Boiler Construction Part-1

MARINE BOILER SERIES: PART 1
A Guide to Boiler Construction

and Design
www.marineinsight.com
Marine Insight©
Marine Boiler Series Part 1: A Guide to Boiler Construction and Design
Publication date: April 2015

Author: Anish Wankhede
Editor : Raunek Kantharia
Published by: Marine Insight

www.marineinsight.com
Graphic Design: Anish Wankhede

Copyright 2015 Marine Insight
NOTICE OF RIGHTS
All rights reserved. No part of this book may be rewritten, reproduced, stored in a retrieval system,
transmitted or distributed in any form or means, without prior written permission of the publisher.
NOTICE OF LIABILITY
The authors and editors have made every effort possible to ensure the accuracy of the information
provided in the book. Neither the authors and Marine Insight, nor editors or distributors, will be
held liable for any damages caused either directly or indirectly by the instructions contained in this
book, or the equipment, tools, or methods described herein.
INDEX
TYPES AND WORKING OF MARINE BOILER
SMOKE TUBE BOILER
WATER TUBE BOILER
COMPOSITE BOILER 1 (1-16)
DIFFERENCE BETWEEN SMOKE TUBE AND WATER TUBE BOILERS
BOILER MOUNTINGS
EXTERNAL MOUNTINGS
2 (17-43)
INTERNAL MOUNTINGS
PROBLEMS IN BOILER MOUNTINGS
MAINTENANCE OF BOILER MOUNTINGS
BOILER CONSTRUCTION
BOILER TUBES- PROBLEMS AND MAINTENANCE
BOILER FURNACE- PROBLEMS AND MAINTENANCE
BOILER REFRACTORY- PROBLEMS AND MAINTENANCE
SUPERHEATER
3 (44-101)
BOILER SHELL
BOILER BURNER
TYPES OF BURNER
4 (102-126)
ADVANTAGES AND DISADVANTAGES
MAINTENANCE AND INSPECTION
COMBUSTION AIR
1
TYPES AND WORKING
SMOKE TUBE BOILER
WATER TUBE BOILER
COMPOSITE BOILER
OF BOILER
DIFFERENCE BETWEEN
SMOKE TUBE AND WATER
TUBE BOILERS
Types and Working of Marine Boiler – Principle of working
Boiler is one such machinery, which is being used on board ships from the very
early days of shipping when there were no propulsion or power generating
auxiliary engines.
During that time, boiler was used to do
all the major works on ships that present
day propulsion and power generating
systems do. With evolution of
technology, a variety of machines took
over the important jobs on ships;
however, advanced boilers are still an
important part of the engine power plant
and cargo operations.
Considering their functionality, the

material used for the construction of
boilers must be such that they can
withstand the immense steam pressure
2
Types and Working of Marine Boiler – Principle of working
and extreme temperature with minimum heat loss to the surroundings.
Normally, carbon steel is used for the construction of pressure vessels, which
are manufactured by open hearth, electric or pneumatic processes. An
important point to be considered for boiler construction is that the strength of
the material used is tested as per the regulatory requirements.
Principle of Working: The marine boiler works on a simple principle of change

in state of water from liquid to vapor form by utilizing the heat energy. The
water is boiled in an enclosed pressure vessel so that the steam generated is
not lost to the atmosphere. The heating source is enclosed in an insulated
furnace to ensure that the heat energy is transferred mainly to the water and
not to surrounding area.
A variety of boilers are used on ships, depending upon their size and type. The
most common types of boiler installed on board are:
3
Types and Working of Marine Boiler – Smoke Tube Boiler
Smoke Tube Boiler
As the name suggests, the heated smoke generated in the boiler furnace is
passed through several tubes surrounded by water in the boiler drum.
Horizontal Smoke Tube Boiler
4
The heat of the smoke in the tubes generates the steam. The smoke tube
boilers are used in a system with less steam quantity and quality. In a ship, a
smoke tube boiler can be described as – horizontal or scotch boiler and
vertical smoke tube boiler
Horizontal Smoke Tube or Scotch Boiler: This is an old type of boiler with
cylindrical furnace surrounded by water inside the shell. The furnace in this
type of boiler is water-cooled, has a large diameter, and is thicker. This leads to
thermal stresses if the boiler is not operated correctly.
Horizontal smoke tube boiler comprises of end plates, which are opposite to
the burner assembly. These flat-ended plates, supported by large steam space,
stay in the upper portion of the boiler. The combustion chamber is supported
by the girder stay at the topside and by the combustion chamber stays. The
mid-section back plates and tube plates are also supported by the combustion
chamber stays.
5
Vertical Smoke Tube Boiler: A vertical smoke tube boiler is more popular and
commonly found on ships. In this boiler arrangement, the furnace is in the
bottom part of the boiler and is attached to the shell by means of ogee ring at
the bottom.
The furnace is fitted with refractory, which contains the produced heat inside
the furnace and also protects the ogee ring from overheating. The combustion
chamber with tube stacks is located above the furnace, where the hot smoke is
passed for heating the water drum. The top of the combustion chamber is
supported by gusset plate that transfers the stresses to boiler shell.
Fire tube boilers are competitive for steam rates up to 12,000 kg/hour and
pressures up to 18 kg/cm2. Fire tube boilers are available for operation with oil
and gas fuels.
6
Types and Working of Marine Boiler – Water Tube Boiler
Water Tube Boiler
Water tube boilers are 2nd generation boilers with modification in the
construction and working principle of the smoke tube boiler. The tubes inside
the boilers are filled with water instead of smoke and hence the thermal
stresses are less as compared to those produced by the smoke tube boiler.
This type of boiler is used where the steam quality and quantity demand is
high. All high pressure boilers are mainly water tube boilers and comprise of
mainly 3 important sections:
• Water drum
• Steam drum
• Tubes
7
Water drum: It is located at the bottom of the boiler and carries the hot water.
The same water is supplied to the steam drum where the steam is generated.
Steam drum: It is located at the top part of the boiler and is fitted with
external and internal mountings, which include safety valves and steam stop
valves (main and auxiliary), to supply steam to the ship’s systems.
Tubes: Modern water tube boiler consists of various types of water tubes with
different functions. The main types are:
• Screen tubes: Placed before the super-heater, these tubes are adjacent to
the furnace and absorb the flame as well as the generated hot gas heat.
Since these tubes are directly exposed to the furnace heat, they are of large
diameter to prevent overheating
• Superheater tubes: They are placed behind the screen tubes to carry
8
Water Tube Boiler
9
the superheated steam from the boiler
• Generating tubes: These tubes connect the water drum and the steam
drum. As the name suggests, hot water is carried upward from water drum
to steam drum where the steam is produced
• Down comers: Down comer tubes transfer the not-so-hot water to the
water drum, where the water is heated up in the generating tube before
going back to the steam drum
Working Principle of Water Tube Boiler: The Water Tube boiler works on the
principle of convection and radiation.
Most modern water tube boiler designs are within the capacity range 4,500 –
120,000 kg/hour of steam at very high pressures. Many water tube boilers are
of “packaged” construction in case oil and /or gas are to be used as fuel.
10
The main features of water tube boilers are
• Forced, induced and balanced draft provisions help to improve combustion

efficiency
• Less tolerance for water quality calls for water treatment plant
• Higher thermal efficiency levels
• High pressure ratings
• Better quality of steam
• Suitable for large capacity system
11
Types and Working of Marine Boiler – Exhaust Gas Boiler
Exhaust Gas Boiler
The exhaust gas boiler and economizer are heat recovery units and types of
water tube boiler. The flue gases from the exhaust of the engine are used to
heat water in the tubes at a specific temperature and limited pressure loss.
A circulation pump is used to continuously circulate the hot water in the water
tubes of the economizer.
The auxiliary steam boiler serves as a steam separator for the entire system
and is thus kept hot and ready to start instantly.
The excess steam produced by the economizer when the main engine is
running at high load, is dumped back to the hot-well using a steam dump
condenser.
The exhaust boiler is provided with a vertical register of double steel tubes
12
Types and Working of Marine Boiler – Exhaust Gas Boiler
having steel gills welded on the tube. This provides a strong rigid structure and
also assists in preventing damages caused by vibrations.
Since hot gases flows from the boiler trunk to heat up the water, the complete
exhaust boiler is prone to thermal expansion, which is controlled by fitting
various tubes and plates.
Tube register, tube support and tube bends are placed in the flow direction of
the exhaust gases. The tube supports are fixed at one side of the inlet and
outlet header to a supporting beam. The other end is kept free of supporting
beam to accommodate for the thermal expansion.
The boiler foundation is provided with footplates, which also support the
structure and absorbs the thermal expansion. For additional strengthening and
support, stays are fitted on topside with lifting eyes bolted to the steel
structure.
13
Types and Working of Marine Boiler – Composite Boiler
Composite Boiler
Another most common type of boiler
found on ships is the composite boiler,
where the exhaust heat of the main
engine or generator engine is used to
additionally heat the water or generate
the steam. Technically, composite boiler
is an integration of exhaust gas boiler
and oil-fired boiler.
A composite boiler can be a water

tube or a smoke tube boiler divided
in two different sections. One section
of the boiler is heated by the burner
and the other by the exhaust gases
produced by ship’s engine.
Composite Boiler
14
Types and Working of Marine Boiler – Smoke Tube vs. Water Tube Boilers
Difference Between Smoke and Water Tube Boilers

Smoke Tube Boiler Water Tube Boiler
Suitable for low pressure range Suitable for high pressure range – 100 bars
High thermal stresses Low thermal stresses
Low quality and quantity of steam High quality and quantity of steam
Less efficient Highly efficient
Large diameter tube Small diameter tube
Heavy in weight Light in weight for same capacity
Risk of explosion is less Risk of explosion is high
16
Marine Boiler Mountings
2
BOILER MOUNTINGS
EXTERNAL MOUNTINGS
INTERNAL MOUNTINGS
PROBLEMS IN BOILER
MOUNTINGS
MAINTENANCE OF BOILER
MOUNTINGS
Marine Boiler Mountings – External Mountings
BOILER EXTERNAL MOUNTINGS

The boiler steam drum is fitted with several internal and external mountings
for ensuring the safety and efficiency of the boiler steam system. These
mountings are important mechanical components that need to be maintained
for trouble-free operation. Following are the important external mountings
fitted over the boiler:
Safety Valves: Safety valve are fitted in two
numbers (pairs) to ensure that the boiler does
not over-pressurize else it may lead to explosion
of the pressure vessel.
The two safety valves are set at different

pressures; one is set slightly lower than the other.
If one safety valve does not lift due to
malfunctioning, there is always a back up valve to
safeguard the boiler. Read complete detail on
safety valve Marine Boiler Series Part 2 eBook. Safety Valve
18
Main Steam Valve: The steam generated in the boiler is delivered to the
engine room system through the main steam stop valve. The function of this
valve is to isolate the steam boiler and pressure from the rest of the system. It
is generally an angle type globe valve of screw down mechanism.
The stop valves are not meant

for throttling and should be
either in fully open or closed
position.
It is important to open the

stop valve very slowly in order
to avoid sudden downstream
pressure rise and effect of
water hammering.
Main Steam Valve
19
Bypass valve: This valve is installed in high-pressure boilers to equalize the

pressure between the boiler and the steam system, when the main steam stop
valve is in shut off position. It is basically a type of shut off valve.
Vent Valve: An air vent valve is provided on top of
the steam drum to vent the air when the boiler is
initially filled or drained with water. The air vent
valve is also kept open during firing up of the boiler
from cold condition and once the steam starts
coming out, the vent is closed.
The vent valve should positively be opened when the

boiler is taken off service, or else with dropping
pressure and air vent closed, implosion of drum can
occur.
The discharge of the vent is generally provided with

Vent Valve
20
a copper pipe, whose end is to be kept near the drain and properly visible
while operating the boiler in above-mentioned condition. This is a type of shut
off valve.
Feed Water Valves: Feed water check valve is installed between the boiler and
the feed water pump. The feed water stop valve is fitted close to the boiler
drum. The check valve includes a spring equivalent to the head of water in the
elevated feed-tank when there is no pressure in the boiler. This prevents the
boiler from flooding by the static head from the boiler feed tank.
The temperature of feed water is kept below 100 °C and therefore ethylene
propylene soft seals are used for check valves.
Boiler Gauge Glasses: A gauge glass shows the current level of water in the
boiler, regardless of the boiler’s operating conditions. Marine boiler is provided
with two independent water level gauge glasses, which are located in front of
the boiler, such that their lowest readings show the water level
21
at least 50mm above the point of overheating of the boiler.

The gauges are also provided with a shut down valve,
drain cocks for gauge glass blow-down, and a protector.
The protector should not hinder the visibility of the
correct water level. The pipes connected to the drain
cock should be such that it opens in the boiler tray near
the drain and is visible for inspection.
As it is an inspection glass and prone to breaking, gauge

glass is fitted with additional safety to avoid the hot
water or steam coming out of the boiler from injuring
or burning the operator. A ball valve is fitted to the
lower end of the gauge glass in order to shut-off the Gauge Glass
water in event of the glass breakage, else the water will blow out and the
sudden reduction in the pressure will lead to flash off into scalding steam.
During normal operation, the ball valve sits down, as there is no flow of water
22
inside the gauge glass. The ball sits down due to its own weight, uncovering
the water inlet to the gauge glass. In case of glass breakage, the sudden flow of
water pushes the ball to block the water inlet of the glass and stop the water
flow.
Sample Valve: A sample valve is provided on the boiler drum whose outlet is
installed in the engine room (mostly in the areas like workshop etc.) along with
a cooler and a valve on the discharge point. This cooler is provided to
safeguard the personnel from steam burn. The cooler is normally sea-water
cooled.
Blow Down Valves: The boiler is fitted with two separate blow-down valves at
different levels.
Bottom blow-down valve: It is fitted at the bottom side of the boiler and is
used to remove sludge or sediments from the boiler. Usually a large (25 -50
mm) key operated valve is fitted at the shipside, along with an intermediate
23
and a blow-down valve near the boiler. This valve might normally be opened
for a period of about 5 seconds, once per shift, depending upon the dissolved
sediments in the boiler water.
Scum blow down valve: The scum blow-down is fitted near the upper side of
the boiler drum i.e. at the normal level of the boiler water in the steam drum.
It is used to remove the floating impurities from the surface of the boiler
water. The discharge of the scum blow down is also connected to the
overboard line. A funnel is provided inside the boiler drum to scum the surface
impurities once the scum blow down-valve is opened.
Other Notable Mountings:

• Supply valves for pressure gauge and sensors
• Waste heat recovery inlet and outlet valves
• Inspection hole
• Manhole door
• Furnace Drain valve
24
Marine Boiler Mountings – Internal Mountings
Boiler Internal Mountings
Just like external mountings, the steam drum of a boiler is also fitted with
internal components, which help in increasing the efficiency of the produced
steam. Important internals mountings used in boiler are:
Attemparator: It is a stack of ‘U’ tubes situated in the lower part of the steam
drum and is always submerged in water. It is used to keep the super-heated
steam temperature within certain desired limit in the final stage.
Steam Inlet
Attemparator Steam Outlet
25
Marine Boiler Mountings – Internal Mountings
Cyclone Separator: Cyclone separator is similar to the filter, which is used to

remove water droplets from the steam to avoid carry over of water in to the
engine room systems.
Baffle Plates: Baffle plates are placed

in the direction of the flow of steam.
Its main function is to reduce the
turbulence effect of the steam and to
improve it’s purity.
Chemical Dosing and Feed Water Pipe

Inlet: The internal part of the steam
drum is provided with pipe ends - one
pipe end supplies chemical for dosing
and the other pipe supplies the boiler
feed water in the steam drum.
Baffle Plates
26
Marine Boiler Mountings – Problems
Scum Blow Down Funnel: A funnel is placed in the steam drum, almost at the
boiler water level, to enable extraction of surface impurities from the water.
Problems in Boiler Mountings

Problems in Valves
Few common problems that are found in steam system valves are:
Leaking gland packing: This is the most common problem seen in the steam
valves. It is due to temperature variation within the valve. Any damage to stem
of the valve will lead to gland leakage.
Leaking valve seat: Valve seat is subjected to high pressure and velocity of
steam, leading to wire drawing effect. Other damages such as scoring and
pitting of the seat may also occur. If the valve is shut too tight, it may damage
the seat.
27
Stuck up spindle: If the valve is not operated for a long period, the stem or
spindle may get stuck due to impurities and deposits on the stem boundaries,
which resist the turning of the spindle. Due to high temperature contact, the
stem will expand and in presence of deposits, will have no room to turn.
Problems in gauge glass:
Wrong water level display: This may be due to impurities in the gauge glass
inlet pipe. The other reason can be foaming in the boiler water, which will
show wrong gauge glass level. If oil has taken access in the boiler water, it will
appear in the gauge glass and the water level will not be at correct position.
Chocked water/steam side: Chocked water/ steam side can be due to lack of
gauge glass maintenance (gauge glass blow down), which leads to salt deposits
accumulating at the corners of the bends and pipes of the gauge glass. Blow
down of gauge glass must be performed at least once a day to avoid this
problem.
28
Stuck ball: The gauge glass comes with a ball which protects and stops the flow
of high pressure and temperature water in case of breakage of gauge glass. If
the gauge glass has not blown down for a long time, it may lead to salt
deposits and can also make the ball stuck. This will not allow any water to
come in the gauge glass. Blow down of gauge glass at least once a day is
therefore very important.
Breakage of glass: The gauge glass can break due to any type of physical
impact. This may lead to high-pressure hot water coming out of the boiler. Due
to sudden decrease in the pressure (as surrounding area is at atmospheric
pressure), most of the hot water will convert in to steam and lead to scalding
injury to the nearby person.
Problems in safety valves easing gear:
Stuck wire: To lift the safety valve manually in the emergency situation, a steel
wire with a handle is used at an accessible and safe place near the boiler. The
29
wire runs through pulleys and connects to the safety valve spindle. Easing wire
slipping out and getting stuck in the pulley are commonly found problems in
the arrangement. It is therefore important to do a weekly inspection and
greasing of the wires.
Jammed pulley: Pulley is a mechanical part, which rotates along a fixed point.
Lack of greasing and accumulation of dust may lead to pulley getting stuck.
Carry out weekly inspection and greasing of the wire to avoid this problem.
Stranding of the wire: The easing gear comprises of a steel wire connected to
the safety valve at one end and lever at the other end. Improper maintenance
and bad quality leads to stranding.
Removed link from the safety valve: The easing wire is connected to the safety
valve with a quick link to lift the valve manually in case of an emergency. This
quick link can be removed easily for maintenance purpose. If the link is not
connected back to the valve, the easing gear will not work in emergency.
30
Problems in manhole doors:
Leaking manhole doors: The major problem with the

manhole door of a marine boiler is the leakage of steam
and water. It generally occurs if the boiler manhole was
opened up for cleaning or inspection. Even if only one
door was opened, the other intact manhole seals may
also leak once the boiler is pressed up.
Boiler Manhole
Problems in pressure transmitter and gauges:
Pressure transmitters and gauges provided in the boilers draw their inputs
from the boiler drum via a small diameter copper pipe. Due to impurities and
deposits in the boiler water, this copper pipe may get chocked, leading to
wrong and erratic pressure readings. The boiler end of the copper pipe is
provided with a small cock valve. Problem in this valve may also lead to wrong
pressure readings in gauges and transmitter.
31
Marine Boiler Mountings – Maintenance
Maintenance of Boiler Mountings
Maintenance of Valves:
• The boiler comprises of different types of valves fitted as boiler mountings

for transfer of water and steam to/from the boiler. The steam stop valve is
of an angle pattern globe valve, which controls the supply of steam from
the pressurized boiler
• The feed waterline is fitted with feed water stop valves after a feed water
check valve to prevent the boiler from flooding by the static head from the
boiler feed tank
• All the steam valves are to be checked for steam leakage from gland and
body-bonnet joint. For a small gland leakage in the pressurized condition,
cautiously tightening the gland packing may help in stopping the leakage;
however, over tightening of the gland packing can damage the
32
gland, leading to more steam coming out at high pressure and causing
burns/ major accidents
• The best and safest way to

stop any leakage from steam
valve is to depressurize the
boiler first. Once the boiler
is at zero pressure, further
time is to be given to cool
down before removing any
steam valve
• Overhauling of the complete

valve is a good move and it
Boiler Mountings
will give a thorough idea about the condition of the complete valve
33
• Replace the gland packing with a new one even if the gland packing seems
OK. Ensure the packing used is same as recommended by the makers
• Replace the joint between the body and the bonnet with steam joint
• Check the valve and valve seat for any damages, pitting and wire drawing
effect
• Lap the valve and seat if required
• Check the trueness of the valve stem
• For feed water valve, isolate the feed water system and depressurize the
boiler before opening any valve
• Check for gland packing and replace the same after removing the old
packing
34
• Clean the valve and valve seat area from the water sediments
• Check for condition of valve and valve seat and lap them as required
• Renew the joint between the bonnet and the body
Maintenance of gauge glass:
The gauge glass of the boiler is important for monitoring safe water level inside
the boiler. The engineer in-charge of the watch must blow down the boiler
gauge glass to ensure the level displayed is always correct.
The gauge glass should also be thoroughly overhauled at each annual survey.
Lack of maintenance can result in hardening of packing joint and seizure of
cocks. If the cock handle becomes bent or distorted special care is to be given
to ensure that the cock is set full open.
35
A damaged fitting should be renewed or repaired immediately. Gauge glasses

often become discolored due to water conditions; they also become thin and
worn out due to erosion. It is therefore advisable to renew gauge glasses at
regular interval of time. A stock of spare glasses and cone packings should
always be available in the boiler spare inventory.
Following things to consider when working on marine boiler water level gauge
glasses:
• If steam passes are choked, a false high water level may be given in the
gauge glass. After the gauge has been tested, a false high water level may
still be indicated
• If the water passages are choked, an artificially high water level may be
observed due to steam condensing in the glass. After testing, the glass will
tend to remain empty unless the water level in the boiler is higher than the
top connection of the gauge glass
36
• Gauge glass levels must be monitored with utmost attention as they are the
only visual indicators of water level condition inside the boiler
• Any abnormal water level must be investigated as soon as it is observed,

with immediate action taken to shut down the burner if necessary
Gauge glass blow down procedure:
To test the correct functioning of gauge glass, the following procedure should
be followed:
• Close the water cock and open the drain cock for approximately 5 seconds
• Close the drain cock and open the water cock
• Water should return to its normal working level quickly. If this does not
happen, then a blockage in the water cock could be the reason, and
37
remedial action should be taken as soon as possible
Boiler Gauge Glass
38
• Close the steam cock and open the drain cock for approximately 5 seconds
• Close the drain cock and open the steam cock
• If the water does not return to its normal working level quickly, a blockage
may exist in the steam cock. Remedial action should be taken as soon as
possible
The authorized officer should systematically test the water gauges at least
once every day with suitable protection for face and hands, as a safeguard
against scalding in the event of glass breakage.
Note: All handles of the gauge glass cocks should be pointing downwards
when in the running condition.
39
Maintenance of glass and accessories:
• The protective guard of the gauge glass should be kept clean. When the
guard is being cleaned in place, or removed for cleaning the gauge should
be temporarily shut-off
• Make sure there is a sufficiently required water level in the boiler before
shutting off the level gauges. Do not to touch or knock the gauge glasses
when cleaning or replacing the guard. After guard maintenance, the gauge
should be tested and the cocks should be set in the correct position
• If the glass needed is to be replaced, it is advisable to depressurize the

boiler (even when the gauge glass cocks and valves are holding) before
maintenance
• Clean the inside of the gauge for any sediments or deposits before replacing
the glass
40
• If the complete gauge is removed for overhauling, check the condition of

the safety ball valve and clean the seating of the same
• Always renew the gauge glass joint when replacing the glass
Maintenance of safety valves and easing gear:
The safety valves of the boiler must be overhauled and pressure tested as per
the SOLAS requirements.
Following things need to be done for maintenance of safety valve:
• For overhauling the safety valve, depressurize the boiler and wait till the
boiler cools down
• Remove the easing gear link
41
• Check for stamping or tag for last overhaul, pressure setting and description
of the valve. Remove the tag or note down the stamping
• Mark the valves as 1 and 2 as per their pressure settings
• Check the condition of the valve and valve seat for pitting, burnout and
wiredrawing effect
• Lap the valve and seat with recommended lapping paste
• Check the lip of the valve seat for any deformation
• Check the tension of the spring and trueness of the spindle
42
Monthly checks:
• Examine the safety valve drain for leakage/ water seepage
• Examine expansion device at the escape pipe
• Examine the lifting gear device, i.e. clean up and grease all sliding parts
Annual checks:
• The safety valve should be tested in operation by raising the boiler pressure
• Expansion and exhaust pipe should be examined at the same time
43
Marine Boiler Construction
3
BOILER TUBES- PROBLEMS AND
MAINTENANCE
BOILER FURNACE- PROBLEMS AND

MAINTENANCE
BOILER CONSTRUCTION BOILER REFRACTORY- PROBLEMS AND
MAINTENANCE
SUPERHEATER
BOILER SHELL
Marine Boiler Construction – Boiler Tubes
BOILER TUBES
Different types of tubes
Boiler tubes can be broadly classified in two categories:
1. Types as per construction:
• Pin tubes
• Studded tubes
• Spiral tubes
• Seamless tubes
Boiler Tubes
45
2. Types as per operation:
Smoke tubes
Used to carry smoke for heat transfer and are surrounded by water in a fire
tube boiler.
Generating tubes
These tubes consist of a large number of small diameter tubes installed in the
direction of the gas flow.
For roof-fired boilers, the generating bank may consist of one or two rows of
closed-pitched tubes. In some latest modern radiant heat boilers, the
generating bank has been omitted to allow the replacement of the water drum
by a distribution header. The generation bank is normally heated by
convection rather than radiant heat. For a set water circulation the tube
diameter is limited to minimum as the ratio of steam to water can increase to
a point where the possibility of overheating can occur as a result of low heat
46
capacity of the steam. The number of tubes is limited to prevent undercooling

of the gas flow, leading to dew point corrosion.
Water tubes
47
Screen tubes
These are larger bore tubes that receive the radiant heat of the flame and the
convective heat of the hot gasses. The large diameter keeps the steam/water
ratio down and thus prevents overheating.
The main purpose of these tubes is to protect the superheater from the direct
radiant heat. On modern marine radiant heat boiler, the screen tube wall is
formed out of a membrane wall.
Water-wall tubes
Contains the heat of the furnace, thus reducing the refractory and insulation
requirements. Water wall tubes normally comes in three designs:
• Water-cooled with refractory covered studded tubes

• Close pitched exposed tubes
• Membrane wall tubes
48
Downcomers
These are large diameter unheated tubes i.e. they are fitted external to the
furnace; their purpose is to feed water from the steam drum to the water
drum and bottom headers.
Riser/Return tubes
These tubes return steam from the top water wall headers to the steam drum.
Superheater tubes
These are small diameter tubes in the gas flow after the screen tubes. Due to
the low specific heat capacity of the saturated steam they require protection
from overheating in low steam flow conditions, for e.g. when flashing.
Superheater support tubes

These are large diameter tubes designed to support part of the weight of the
superheater tubes.
49
Tube temperature for the water-cooled sections is considered to be saturation

temperature + 15oC. Solid drawn mild steel is generally used for the
construction of superheater support tubes.
Tube temperature for convection superheater sections is considered to be final

superheat temperature + 30oC. For radiant heat, higher temperature is
considered. For Superheater tubes operating above 455oC a chrome
Molybdenum alloyed steel is required.
From the graph, it can be seen that for carbon
steel there is a rapid drop in strength above
430oC. Long term overheating is a condition
where the metal temperature exceeds the
design limit for a long period. The mechanical
strength is reduced as a function of the increase
in temperature.
Deposits on the external surface and thin gas

film layer aid in reducing the metal
temperature. Deposits on the inside increase
tube metal temperatures.
50
Marine Boiler Construction – Problems in Boiler Tubes
Problems in Boiler Tube

Common problems in boiler tubes are:
1. Short Term Overheating
Short term overheating occurs when the boiler tubes are exposed to sudden
change in temperature because of following reasons-
• Low water level
• Chocking of tubes
• Major load swings
• Excessive heat input
• Wrong/rapid start-up procedure

51
The short term overheating can be seen as a thin lip opening along the
longitudinal direction of the tube. It causes extensive tube bulging and large
fish mouth appearance.
Short Term Overheating
52
2. Long Term Overheating:
In long term overheating, the tube is exposed to a longer duration of abnormal

operation. Following are the various reasons for this problem:
• Partial restriction in the steam or water flow
• Excessive heat input from burner
• Gradual accumulation of scale or deposit
• Steam blanketing in horizontal or inclined tubes
• Operation at temperature slightly above oxidation limits of given steel tube
(450 °C for carbon steel)
Indications of long term overheating:
• Small to moderate bulging

• Small to moderate reduction in wall thickness
• Normally accompanied by thermal oxidation
• Found in superheaters, re-heaters, water walls
53
3. Damage due to Hydrogen:
Hydrogen damage of boiler tubes is normally caused by a corrosive reaction

that occurs between the steam and steel:
Fe + H2O = Fe3O4 + H2
In the above reaction, the

hydrogen released reacts with
the carbides which in-turn
decarburize the steel and forms
methane gas at grain
boundaries.
This also results in decrease in

the strength of the material
and leads to localized corrosion
in the tubes.
Hydrogen Damage
54
This type of damage generally occurs:

• In the water-wall tubes operating above 68 bar pressure
• Beneath heavy deposits
• Where corrosion releases atomic hydrogen
If the tubes are damaged due to hydrogen, it can be identified with following
signs:
• Thick-lipped damage along the longitudinal section of the tube
• Brittle appearance in the damage section
• Blown out tube creating window section
4. Damage Due to Oxygen:
Oxygen pitting occurs with the presence of excessive oxygen in boiler water. It
can occur during operation as a result of in-leakage of air at pumps or failure
in operation of pre-boiler water treatment equipment. This may also occur
during extended out-of-service periods, such as outages and storage, if proper
55
procedures are not followed in lay-up.
Non-drainable locations of boiler circuits such as superheater loops, sagging

horizontal superheater, re-heater tubes and supply lines are mainly
susceptible.
Oxygen Damage
56
This type of damage generally occurs near:

• Economizer feed-water inlet on operating boilers
• Flooded or non-drainable surfaces
If the tubes are damaged due to oxygen, it can be identified with following
signs:
• Aggressive localized corrosion and loss of tube wall
• Reddish-brown hematite (Fe2O3) or “rust” deposits or “tubercles”
• Hemispherical pitting beneath deposits
5. Damage due to Caustic Attack:
The boiler water carries impurities and deposits, which sit on the inner
diameter of the tubes, causing caustic attack. This drastically increases the
stress and strain in the tube walls and any abnormal operation can lead to
damage in the affected tubes.
57
Caustic attack on tubes leads to:

• Diminishing cooling water flow in the tubes
• Boiling of Local under-deposits and concentration of boiler water chemicals
• Under influence of pH it results in corrosive attack at the inner surface,
breaking the protective magnetite layer
Caustic Attack
58
6. Corrosion Attacks:
Corrosion in the boiler tubes can be due to several reasons. Some of the types
of corrosion that affects the life of boiler tubes are:
Stress corrosion: The stress corrosion is commonly seen in austenitic or

stainless steel superheater materials. It leads to trans-granular and inter-
granular cracks that propagate in the
tubes. The stress corrosion rate is much
faster if both high tensile stresses and
corrosive fluids are present together.
Signs of stress corrosion:

• Brittle type thick wall cracks
• Seen generally near tube attachments
• Crack propagating from internal
diameter
Corrosion Attack
59
Waterside corrosion fatigue: Tube damage occurs due to the combination of

thermal fatigue and corrosion. Corrosion fatigue is influenced by boiler design,
water chemistry, boiler water oxygen content and boiler operation.
A combination of these effects leads to the breakdown of the protective

magnetite on the Internal surface of the boiler tubes. The loss of this
protective scale exposes the tubes to corrosion. The problem is most likely to
progress during boiler start-up cycles.
Signs and location of waterside corrosion fatigue:

• Buck-stay attachment, seal plate and scallop bars are most susceptible to
this type of corrosion
• Wide trans-granular cracks normally adjacent to external attachments
Fireside corrosion: The outer surface of the tubes experiences high

temperature fatigue stress due to soot-blowing, improper boiler operation,
normal shedding of slag etc. This thermal stress with other cyclic stresses can
60
initiate cracking of tubes with less elastic external scale, which will expose the
base material to repeated corrosion.
Signs and location of fireside corrosion fatigue:
• Most commonly found on the furnace wall tubes of drum type boilers
• Series of cracks on the outer diameter of tube, propagating in the tube wall
• Elephant hide, alligator hide or craze cracking appearance (a thick russet

appearance to the skin due to furrowing or cracking)
7. Acidic Corrosion:
The acid attack on the boiler tubes arises due to poor boiler chemical dosing or
residual acids trapped in discontinuities post ‘passivation cleaning process’.
61
Marine Boiler Construction – Maintenance of Boiler Tubes
Signs and location of acid corrosion:

• Occurs in the Inside of the boiler tubes
• Irregular pitting marks on the internal diameter of the tubes
• Swiss cheese appearance if the acid attack is very high
Maintenance of Boiler Tubes

Boiler tubes are responsible for heat exchanging process inside the marine
boiler. It is of extreme importance to carry out regular inspections and cleaning
of boiler tubes to ensure that heat is transferred to the water inside the boiler
in an efficient manner for generating the steam. Any interference in the heat
transfer will lead to overheating of the tubes, which can even lead to a major
boiler fire.
Cleaning: This process involves internal and external cleaning of tubes to

remove deposits and impurities. Cleaning processes and intervals varies
according to the type of the boiler (water or smoke tube).
62
Cleaning of Water Tubes:
In water tube boiler, since the hot gases passes over the tube surface, it is
important to remove the deposits and soot from the outer surface. The
internal cleaning cannot be performed frequently as all the tube openings are
inside the water and steam drums. This is when chemical dosing of boiler
water comes into action.
Water washing is the most commonly applied method to clean the soot
deposits over the boiler water tubes . As most of the deposits consist mainly of
non-soluble particles held together by a water-soluble bonding material, water
washing will have the following benefits-
1. Dissolves the bonding material.
2. Washes away the loosened insoluble deposits.
63
The procedure for soot removal with water washing is as follows:
• Shut off the power for burner and pull out the burner assembly from the
boiler furnace
• Wait approximately 10-20 minutes for the boiler furnace to cool down
• Open furnace drain valve and check that the pipe and drain are not blocked
• Unlock and remove the inspection hatches of the smoke outlet box located
on top of the boiler
• Use a hand water lance. Direct a jet of fresh water at each of the vertical
uptakes
• Flush carefully over each tube for 20-30 seconds with a good flow of water
jet
64
• Water pressure should be between 4 and 6 bar
• Allow time for the washing water to drain from the furnace floor and check
the drain outlet has not become blocked
Water Washing of tubes

Note: Care should be taken not to let water get in contact with burner throat refractory.
65
Cleaning of Smoke Tube Boiler:
In the smoke tube boiler, the flu gases passes through inside of the tubes,
which are surrounded by water. If the tubes are covered by soot (internally) or
by mud (externally) the heat transfer rate will decrease resulting in dipping of
overall boiler efficiency.
For cleaning the tubes, the complete
boiler needs to be shut down and the
water to be drained off. Following
procedure is to be performed:
• Shut off the power for boiler
• Let the boiler cool down for

sufficient time
Smoke Tubes • Start draining the boiler once the

66
pressure inside the boiler is zero
• Check the local regulations (if in port) before carrying out boiler blow down
procedure
• Check and inform the dry dock personnel if in dry dock before the blow
down
• Once the boiler is completely empty of water, open the top most manhole
door and check the real water level
• Open other manholes on the boiler
• Remove the heat resistant lagging to access the smoke box of the boiler
from both the sides
• Clean the boiler tubes internally by using a boiler tube-cleaning tool

67
(Pneumatically supplied long rod with brush fitted at the end along with
water supply arrangement. The brush rotates due to air pressure inside the
tube and water spray softens the hard deposited soot)
• If the tool is not available, take a rod and a cleaning round metal brush
• Weld the brush at one end and manually clean the tubes by to and fro
motion of the rod
• Fresh water to be used when cleaning the ID of tubes
• The outer surface of the tubes can be cleaned by using fresh water jet spray
through the manhole doors
• Ensure the boiler drum drain valve is opened and clear
• Renew all the gaskets for smoke box cover before installation
68
• Renew all manhole door gaskets even if the gaskets seem in good condition
Welding:
Welding on boiler tubes is done either for temporary repairs or while re-tubing
the boiler by removing the old tubes and inserting the new ones. For repairing
by welding, following points to be considered:
• Welding to be performed by approved welder only
• The boiler power is to be shut down and the boiler is allowed to cool before
working
• Ventilation is established for working
• Before performing re-tubing in fire tube boiler, notify the owner and class
approval body for carrying out pre and post inspections
69
• The ends of the tubes must be firmly rolled,

beaded and welded in a fire tube boiler
• Where the tubes do not exceed 1 1⁄2 inches in

diameter, the tube sheet may be beveled or
recessed to a depth at least equal to the
thickness of the tubes and the tubes should be
rolled into place and welded. In no case shall the
tube end extend more than 3/8- inch beyond the
tube sheet
• Tube ends not subjected to direct radiant heat of

the furnace may be rolled and seal- welded
without beading provided the tube ends extend
in the range of 1⁄4-inch to 5/16-inch through the
tube sheet; and the throat of the seal-weld is in
the range of 3/16-inch to 5/16-inches Welding on the renewed furnace
panel wall tube
70
• Tubes to be re-expanded once the welding is completed
• The expanding of tubes can be done either by Prosser method or by rolling

method depending on the tube’s diameter
• In the water tube boiler, tubes’ ends and neck can be fusion welded to the
boiler drum without expanding or flaring only if the material used and
welding comply with the SOLAS and manufacturer requirement
• In water tube boiler, forge or fusion welding may close ends of stub tubes
• For boiler and super heater tubes, seal welding can be applied into fittings
or headers once they have been expanded and flared, provided the
materials in the fittings or headers complies with the SOALS regulations
• Repairing of bulges in tubes in water-tube boilers is permissible when the

area to be repaired does not exceed 2 inches in maximum dimension and
71
there are no more than three such repairs in any one tube
Plugging:
The boiler tube may get damaged, which can cause leakage and hamper the
boiler operation. Since boiler is important machinery for engine room
operation of the ship, sometimes temporary repairs are followed to stop the
leakage and resume boiler operation.
One such operation is plugging of the leaky boiler tubes. In this method, first
the leaking tube is determined followed by the plugging of the tube. The
plugging procedure will depend on the type of the boiler.
For smoke tube boiler, following procedure to be performed while plugging

any leaky tube:
• Stop and cool down the boiler

72
• Perform hydrostatic testing to identify which tubes are leaking
• One end on the damaged tube can be collapsed inside the tube plate after
the other end has been cut clear off the tube plate. Then pull out the
damaged tube
• Insert a short length tube in its place and weld it
• Insert a tapered tube plug and perform tack welding to hold the plug in
place. The alternate method to hold the plug is to use a long steel bar
threaded and bolted at two ends, holding the plug from its center
• Once the plugging of tubes is completed, they must be hydraulically

pressure tested to confirm any leakages
• Since this is a temporary repair, a permanent repair must be planned as

soon as possible
73
For water tube boiler, following procedure to be performed while plugging any
leaky tube:
• Stop and cool down the boiler
• Open and swing out the burner door assembly and check for any sign of
water leakages
• If the leakage is not visible from the burner side, open inspection door and
furnace entrance door
• While checking the leakage, ensure the boiler feed pump is running
• The leakage will be indicated by pressurized water flow
• To find the leakage, operator may have to enter the generating tube section
74
• If no leakage is detected in the

main boiler, check the exhaust
gas economizer for water tube
leakage
• The leaky tube can be cut and

plugged
• Once the leaky tube/tubes are

plugged, ensure to renew with
new register or tubes as
prolong operation with less
tubes heightens the risk of
Plugged tube further damage to the exposed
tubes
Plugging of Furnace Tubes
75
Marine Boiler Construction – Boiler Furnace
Boiler Furnace
The furnace is the space in the boiler where the initial process of steam
production takes place. Heat is generated within the furnace and transferred
to boiler water to produce steam. It is important to ensure the furnace is
properly maintained to avoid heat loss at the initial stage of combustion.
Types of Furnace:
A boiler furnace can be broadly cassified by the method of construction to

following types :
1. Forging: The forging furnace is used for preheating billets and ingots to
attain a ‘forge’ temperature. The furnace temperature is maintained at
around 1200 to 1250°C. Forging furnaces use an open fireplace system and
most of the heat is transmitted by radiation. The typical loading in a forging
furnace is 5 to 6 tonnes with the furnace operating for 16 to 18 hours daily.
76
2. Rerolling mill furnace: Rerolling furnace can be further classified into:
a) Batch type: A box type furnace is employed for batch type rerolling mill.
The furnace is basically used for heating up scrap, small ingots and billets
weighing 2 to 20 kg. for rerolling. The charging and discharging of the
‘material’ is done manually and the final product is in the form of rods,
strips etc. The operating temperature is about 1200 o C.
b) Continuous pusher type: The process flow and operating cycles of a

continuous pusher type is the same as that of the batch furnace. The
operating temperature is about 1250 °C. The material or stock recovers a
part of the heat in flue gases as it moves down the length of the furnace.
Heat absorption by the material in the furnace is slow, steady and uniform
throughout the cross-section compared with batch type.
c) Continuous steel reheating furnaces The main function of a reheating

furnace is to raise the temperature of a piece of steel, typically to between
77
900°C and 1250°C , until it is plastic enough to be pressed or rolled to the

desired section, size or shape. The furnace must also meet specific
requirements and objectives in terms of stock heating rates for
metallurgical and productivity reasons.
All furnaces have the following components:
• Refractory chamber constructed of insulating materials to retain heat at

high operating temperatures
• Hearth to support or carry the steel, which consists of refractory materials

supported by a steel structure, part of which is water-cooled
• Burners that use liquid or gaseous fuels to raise and maintain the
temperature in the chamber
• Exhaust passage to remove combustion exhaust gases from the chamber

78
Corrugation: The plain boiler furnace geometry is corrugated to strengthen

and to increase the heated surface area. Due to their shape, they can
withstand elevated operating parameters of a high pressure boiler.
Mainly five types of boiler corrugations are available:
1. Leads Suspension: When corrugations are not more than 8 inches from
center to center, and not less than 21/4 inches deep.
79
2. Deighton and morrison: In this type, the corrugations are not more
than 8 inches from center to center, and not less than 11/2 inches deep.
3. Fox: In this type, the corrugations are not more than 6 inches from
center to center, and not less than 11/2 inches deep.
80
4. Purves: In this type, the corrugations are not more than 9 inches from
center to center, and not less than 13/5 inches deep
81
Marine Boiler Construction – Problems in Boiler Furnace
Problems in Furnace
Boiler furnace is a primary component where the heat generation and transfer
take place. A small change in the efficiency of the furnace will lead to a large
change in the specific fuel consumption of the boiler. Following are a few
common problems related to boiler furnace:
• Heat loss from the furnace due to poor shell insulation - The heat generated
in the furnace is transferred to the boiler shell but it is contained by the
outside insulation. Any damage in the insulation will lead to decrease in the
furnace efficiency
• Damage in the furnace refractory
• Overheating of inner layer of refractory
• Leakage of furnace gas outside the boiler furnace

82
Marine Boiler Construction – Problems in Boiler Furnace
• Leakage of air in to the furnace
• Damage in the furnace door
• Crack near the welding of furnace door leading to gas leakage
• Damage to bottom blow-off pipe due to direct exposure to heat
A bottom blow-off pipe when exposed to direct furnace heat shall be

protected by firebrick or other heat resisting material so arranged that the
pipe could be inspected when required.
When the pressure in the furnace automatically controls the intake damper,
furnace pressure is maintained slightly below the atmospheric pressure.
83
Marine Boiler Construction – Maintenance of Boiler Furnace
Maintenance of Furnace
Following points sre to be considered for carrying out furnace maintenance:
• Maintain the boiler insulation at any cost
• Maintain the refractory inside the boiler furnace
• Maintain proper sealing from manhole doors of the furnace
• Ensure to maintain the maximum surface temperature of boiler shell at

about 50 °C
• If the furnace has to be rebuilt, better to use ceramic fiber blanket

insulation. If refractory brick is required to withstand rough handling, an
outer layer of ceramic fiber can be used
84
• Maintaining a slight positive furnace pressure can control air leakage in the
furnace
• Cover the bottom blow off pipe by firebrick or other insulating material in
such a way that the pipe may be inspected when required
Furnace Inspection:
• Check overheating distortion on furnace crown
• Check for flame impingement and dry cracks due to impingement
• Check for hairline cracks in boiler brickwork (refractory) due to changes in

furnace temperature
• Check for corrosion
85
• Check brickwork protecting the foundation. If found damaged, it may cause

distortion of bottom plating
• Check condition of water wall tubes
• Check for water leakage if visible during furnace inspection in water tube
boiler
• Check for overheating of soot blowing tubes whose opening can be seen
from the furnace
• Check the condition of screening tubes
• Examine the furnace end of superheater visible through screen tubes
• Check the gas baffle condition above and below the superheater
86
Marine Boiler Construction – Boiler Refractory
Boiler Refractory
The basic requirement of boiler refractory materials is that they should contain
the heat generated in the furnace. They therefore must have good insulating
properties and should be able to withstand high temperatures.
They must also have sufficient mechanical strength to resist the forces set up
by the weight of the adjacent brickwork, to withstand vibration and the cutting
and abrasive action of the flame and flue dust. The materials must also be able
to expand and contract uniformly without cracking.
At present no single refractory material can be used economically throughout

the boiler, and the choice of suitable materials for various parts of the boiler is
generally governed by the temperatures to which the refractor material will be
subjected.
87
Marine Boiler Construction – Boiler Refractory
Types of Refractory
1. Firebricks
These are formed into bricks and then fired at high temperatures in special
kilns. They are made from natural clay containing alumina, silica and quartz.
2. Monolithic Refractories
The monolithic refractories are supplied in an unfired state and installed in the
boiler. They are fired in situ when the boiler is put into service. This type can
be further subdivided into:
• Moldable refractory: It consists of natural clay added with calcified fire clay
that has been crushed and graded. This is used where direct exposure to
radiant heat takes place. It must be pounded into place during installation
• Castable refractory: The castable refractory is not meant for direct

exposure of flame. This refractory is thus placed behind water walls and
88
Marine Boiler Construction – Boiler Refractory Problems
other parts of the boiler where it is protected from direct radiant heat. The
installation process is similar to that of building concrete
• Plastic chrome ore: This refractory bonded with clay, is used in the
construction of studded water walls. It can resist high temperatures but has
less mechanical strength, and is pounded onto steel studs welded to the
tubes. These studs provide both strength and means of attachment for tile
refractory
Problems in Boiler Refractory
• Spalling: Breaking away of refractory layers
• Slagging: Softening of the bricks to a liquid state due to presence of sodium

or vanadium in the boiler fuel
• Shrinkage cracking: Refractories are weaker in tension than in compression

89
Marine Boiler Construction – Boiler Refractory Installation
or shear. Thus if compression takes place due to the expansion of the brick
at high temperature, sudden cooled cracking may occur
• Failure of brick securing devices
90
Repair and Installation of Refractory
It is the duty of ship’s engineers to check the condition of refractory at regular

intervals of time. Any damage to the refractory will definitely increase the time
for producing the required steam pressure, which means increase in fuel
consumption of the boiler.
A quick way to examine refractory is to open the burner door and check the
refractory condition. This will only take few minutes. If any part of the
refractory is broken, ensure a temporary repair with available refractory at the
earliest possible chance.
Before repairing the refractory material, shut off the burner and boiler. Check
the properties of spare refractory mixture available onboard.
Engineers must know the mixing procedure of the paste (ratio of portion of
refractory paste to water), time and setting condition.
91
Refractory Installation
If the refractory requires following a firing rate for setting up, it should be done
accordingly. The engineers must ensure to replace temporary repairs with
permanent ones (performed by qualified shore personnel) according to the
manufacturer requirements.
92
Apart from the plastic chrome refractory, which uses tubes studs for support,
other refractories must be supported by wire, external studs etc. provided as
securing arrangements.
To prevent undue stresses in the refractory, ample expansion spaces must be

provided. Care must be taken to ensure these spaces do not become blocked
in any way as this can cause the refractory to break away from its attachments
and bulge out, with the danger of possible collapse.
Ensure that when choosing and installing suitable materials for the boiler
refractory, acid and alkaline substances are kept apart as at high temperatures
they can react to form salts, which destroy the effectiveness of the refractory.
93
Marine Boiler Construction – Superheater
Superheater
A superheater is an additional small boiler, which is fitted in the water tube

boiler for converting the saturated steam or wet steam in to dry steam for
engine room machinery systems.
It is normally installed between water and steam drum across the

superheating gas passage.
Construction: Superheaters in marine boilers are mainly of U tube or W tube

construction depending upon the availability of space for superheater and
steam generation capacity of the boiler.
U type superheater comprises of U tubes preferably placed vertically to the gas

passage as this arrangement prevents slagging of the tube when placed in
horizontal position. In this type, the tubes are supported by support plate
hanging off in one of the water cooler tubes, whose diameter is increased to
94
accommodate the support plate. Division plates are also welded on the
headers. The super-heater inlet and outlet flanges are mounted on the same
side.
In W tube type superheater, the tubes are placed horizontal to the flow of hot
gases. The advantage of this type is that it overcomes the problem of deposits
on the gas side of the superheater tubes and also avoids chocking of gas
passage as there is greater length, breadth and gap between tubes.
The tubes of superheater are made of solid drawn mild steel which works at
temperature of up to 455 °C . Where higher temperature operation is involved
(up to 560 °C ), molybdenum steel tubes are used.
The superheater is also provided with a separate safety valve, which is set at
pressure well below that of the drum safety valve setting pressure. This is done
to ensure that flow of steam is maintained in the superheater under blow off
condition.
95
Inspection:
On the gas side of the superheater, access space is provided for general
cleaning and maintenance.
Check the following when inspecting superheater of a marine boiler-
• Sagging of superheater tubes between their supports
• Build-up of deposits in the superheater tubes
• Bonding slag deposits caused by vanadium bearing ash
• Support lugs situated in a high temperature zone and susceptible to

thermal stress failure
• Condition of division and support plates

96
Marine Boiler Construction – Boiler Shell
• Cracks In superheater due to poor steam-raising procedures, lack of

expansion, or from continual carry-over of water droplets
• Condition of soot blowing arrangement for superheater
Boiler Shell
The boiler shell is pressure vessel constructed to contain the extreme pressure
generated inside the boiler. The shell covers the water and combustion sides of
the boiler and acts as a barrier between the atmosphere and boiler’s internal
area to minimize heat loss between the two.
All the external mountings and manholes are installed over the boiler shell by
cutting an opening to accommodate all the accessories. The shell strength
should be properly maintained considering the number of mountings and
cuttings incorporated in the boiler shell.
97
Construction:
Boiler shell is constructed either by riveting or welding several plates making

one complete pressure vessel. For riveted construction, plates and steam
space stays must have tensile strengths ranging between 430 – 560 MN/m2
provided the percentage of elongation is not less than 20 percent on a
standard test length.
For welded type, the shell plate strength should be between 400 – 450
MN/m2. If the plates are to be flanged, the strength requirement will decrease
but the percentage elongation must be increased to 23 % on a standard test
length.
The boiler shell comprises of several mountings and manhole doors for which
the shell is cut. This will weaken the strength of the shell and hence
compensation is required. For any hole cut in the shell, additional material
with a diameter greater than 2.5 x plate thickness + 70mm must be provided
98
for compensating the loss of strength due to material cut out.

The largest holes cut in the shell
include the manholes, and where
these are cut in the cylindrical
portion of the shell they must be
arranged with their minor axis
parallel to the longitudinal axis of
the boiler.
This is because the stress acting

upon the longitudinal seam is twice
of that acting upon the
circumferential seam.
Thus the shell must not be

weakened more than necessary
Boiler Shell along its longitudinal axis.
99
Inspection: The boiler shell must be inspected at every dry dock or during
major boiler repair. Following things are to be checked while inspection:
• Ensure to wear face mask while removing the insulation lagging from shell
• Before removing the metal sheet which covers the insulation, check for
black smoky marking in the sheet near the furnace side, which indicates
shell leakage
• Remove the sheet and insulation lagging to access the shell
• Check for cracks and bulging in the shell
• Check carefully the area where manhole doors are welded to the shell for
cracks and deformation
• Check carefully the area where valves and fittings are welded to the shell
100
for cracks and deformation
• Ensure lagging material is sufficient to insulate the high temperature shell
• Check insulation lagging is not wet near water/ steam side of the boiler,
which indicates shell leakage
Maintenance and Repair
The major maintenance done on the boiler shell is repairing welding cracks,
cracks on the surface and bulge section in the shell.
101
Marine Boiler Burner and Combustion
4
BOILER BURNER AND
TYPES OF BURNER
ADVANTAGES AND
DISADVANTAGES
COMBUSTION MAINTENANCE AND

INSPECTION
COMBUSTION AIR
Marine Boiler Burner and Combustion- Types of Burners
Types of Marine Boiler Burner
In a marine boiler, oil fired burner is normally used with diesel or heavy fuel oil
as burning fuel. The fuel to be used has to be clean and with correct
temperature and viscosity for rapid combustion.
This is to ensure that the fuel is at
right atomization that will turn the
fuel into micro droplets for
efficient combustion.
Temperature is a critical factor

during combustion, as a lower
than normal temperature will lead
to increase in the size of droplets,
resulting in poor combustion and
producing soot and smoke.
Burner
103
If the fuel temperature is too high, the droplets will be too small causing
rapidly burning of the fuel near the burner tip. For a marine boiler, three basic
types of burners are used:
1. Pressure Jet Burner

2. Air or Steam Blast Atomizer
3. Rotary Cup Burner
Pressure Jet Burner
The main purpose of boiler burner is to break the oil into fine droplets i.e. to
atomize the fuel in correct manner so that efficient combustion can be
achieved. In pressure jet burner, an orifice or nozzle is fitted at the end of a
pressure tube, which atomizes the fuel in to fine droplets.
Atomization of fuel also mainly depends on the flow rate of the fuel from the
burner’s end. The difference in the pressure of the fuel before and after the
104
nozzle controls the flow-rate of the fuel from the burner. Hence, if the flow
rate of the fuel from the burner is reduced to 50%, it will affect the
atomization by a drop of 25%. To overcome this problem, this type of burner is
supplied with different sizes of nozzles (having different diameter of orifice),
which can be interchanged as per the flow rate of the fuel and the boiler steam
load.
Pressure Jet Burner
105
The fuel pressure required for pressure jet burner may vary from 7 bar to 15
bar depending upon the design of burner and load of the boiler. The maximum
required viscosity at the burner inlet is normally 15 cst and both diesel and
heavy oil can be used as fuel.
Advantages of Pressure jet burner:
• Simple in construction
• Economical in maintenance
• Variety of sizes available for different boiler loads
• Can be accommodated in all type of furnaces
• Produces variety of flame: short and fat, long and thin
106
Disadvantages:
• Limited turndown ratio for same nozzle size- 2:1
• Nozzle hole prone to frequent clogging
• Burner requires highest oil- pre heat treatment
• Nozzle cleaning to be carefully done as it can be damaged easily
• Requires frequent maintenance
• Inefficient at higher boiler load
2. Air or Steam Blast Atomizer
The working of this type of burner is similar to that of a pressure jet, with an
107
addition of high pressure steam/air supply arrangement. The oil is thus

sprayed in the path of the high pressure air or steam which helps the fuel for
atomization. Normally air is used during the initial starting of the burner and
then steam takes over the operation.
Air/ Steam Atomizing Burner
108
A convergent divergent nozzle is used to convert the pressure energy to kinetic

energy, which results in a high velocity jet of steam and enables atomized oil is
sprayed in its path. The steam side have tangential nozzle, which provides
rotatory motion to the fuel for efficient combustion.
The fuel pressure required for pressure jet burner may vary from 10 bar to 21
bar depending upon the design of the burner and load of the boiler. The
maximum required viscosity at the burner inlet is normally 15 cst and both
diesel and heavy oils can be used as fuel.
Advantages:
• Robust construction
• High Turndown ratio of 4:1
• Efficient combustion over whole firing range

109
• Air fuel ratio can be adjusted for achieving higher efficiency
• Good combustion of heavy fuel oil
Disadvantages:
• Combustion depends on steam/ air supply
• Additional maintenance of connections and piping for air and steam
3. Rotary Cup Burner
As the name suggest, this burner comprises of a burner nozzle covered by a

rapidly rotating cone. The fuel oil is carried on to a nozzle that is centrally
located within the rotating cone. As the fuel oil moves along the cup, due to
absence of centripetal force the oil film becomes thinner in its course as the
circumference of the cup increases.
110
Rotary Cup Burner
111
Ultimately, the fuel is discharged from the tip of the rotating cone in the form
of fine atomized spray.
The atomization achieved in the rotating cup burner has a very high turndown
ratio as compared to that of pressure jet burner, as atomization is achieved by
the rotating cup rather than pressurizing the fuel supply to the nozzle.
Advantages:
• Good turndown ratio of 4:1
• Good atomization of heavy fuel oils
• Lowest oil pre-heat temperature required for atomization
• No high pressure fuel in the line
112
Disadvantages:
• Complex in construction
• Costly to maintain
• Electrical consumption and connections required for the cup drive
Pilot or Ignition Burner:
In some marine boilers with main burner firing in heavy fuel oil, it is very
difficult to initially start the boiler with the main burner. For start up of such
boiler, a separate pilot or ignition burner is provided which uses diesel oil as
fuel.
This enables the pilot burner to ignite even at the coldest condition the ship
faces at sea. The pilot burner has a separate diesel oil piping and pump
113
arrangement. The heat source is provided by two electrodes, which are used
for igniting the pilot flame and are fitted to a high voltage ignition transformer.
The pilot burner is allotted with a limited time of ignition, during which it acts
as a source of heat for the main burner and once the time is over, the pilot
flame goes off.
Pilot Burner
114
Marine Boiler Burner and Combustion – Maintenance and Inspection of Burners
Maintenance and Inspection of Boiler Burner
The maintenance of the complete burner assembly includes inspection main

burner, burner register and flame stabilizer, atomizer, pilot burner and fuel oil
system.
Main Burner Assembly
115
The maintenance depends either on the maker’s instruction or on the

condition of burner parts (breakdown maintenance); but a general overview of
when and how the maintenance to be done for different systems and parts
associated with the boiler burner is explained below:
A two weekly routine should be followed for maintenance of the following-
Fuel Oil Supply System
• Check fuel pipe work for any leakage
• Check flanges, joints and connections for leakages
• Check the manual valves are operating properly
• Check there is no leakage from any part of the valve (i.e valve gland etc.)
116
• Check the condition of lagging on the heavy oil pipes
• Check the tracing steam lines are working fine
• Check all the steam traps in the tracing steam lines are in working condition
• Clean and inspect the heavy oil filters provided in the line
• Ensure pneumatic/ solenoid valves installed before pilot and main burner
are working correctly
• Ensure the fuel supply pump is changed to standby and all parameters are
in normal operating range
• Ensure all the line filters are clean
117
Main Burner:
• Check the condition of nozzle for clogging
• Check there is no leakage or dripping from the burner
• Check all the connections are tightened and wiring is in good condition
• Check the solenoid valve controlling the fuel in the main burner is working
fine
• Ensure there is no leakage from the solenoid valve connection
• Check and clean the cup for hard deposits in rotary cup burner
• Check the burner nozzle size is as per the load demand of the steam
118
• Ensure the trip limit switch on the burner door is working fine as the boiler
will not fire until the door is properly shut
• Check the oil passage in the burner is cleaned with diesel oil and is free
from HFO deposits
• Ensure the fan inlet is kept clean off all deposits and obstructions
• Make sure the burner register is kept clean
• Check the air passage to register for deposits and dust
• Ensure flame stabilizer is inspected and kept clean from carbon deposits
• Flame stabilizer should be checked for heat corrosion
119
Atomizer:
• Clean the atomizer before inspection
• Use paraffin to soak the atomizer to loosen the hard sticky carbon deposits
• Use soft metal scrapper to remove the hard deposits (never use hardened
scrapper as it can damage the atomizer surface)
• Check for surface damage
• Check and clean all the holes in the atomizer
• Change the O-ring every time the atomizer is opened
• Before changing the cap nut, ensure the threads are covered with a non-
hardening high temperature compound
120
Ignition Burner:
• Check and clean the burner nozzle
• Check the atomization of fuel in the workshop. If the atomization is poor

even after cleaning the nozzle, replace it with a new one
• Clean the electrodes with electro-cleaner solution
• Check electrodes for damages
• Check the condition of ceramic insulation of the electrodes for any damage
• While performing maintenance, ensure not to change angle of the

electrodes with respect to the nozzle as it may cause problems in ignition,
instability and building up of carbon deposits
121
Forced Draft Fan
• Remove and overhaul the electric motor as per PMS
• Dismount the nuts that fix the front plate. Remove the front plate by means
of a lifting device or tackle
• Dismount the end bolt and plate of the shaft, and replace the end bolt by a
similar short bolt
• Mount a wheel-puller on threaded holes located on the hub plate. Tighten

the wheel-puller until the impeller is loose
• Dismount the wheel-puller and end bolt once the impeller is loose. The
impeller can now be pulled out from the spiral casing
• Clean the impeller carefully as dust or deposits causes imbalance or
122
vibration
• High pressure compressed air cleaner to be used for cleaning the deposits
• If deposits are hard, scrapper tool to be used
• Check for any water in the spiral casing and same should be drained off
• Check for fuel accumulation in the casing and find out the cause for the
same
• Ensure the impeller is properly cleaned and balanced while installing it on

the shaft
• During starting, check for any sign of vibration
• If vibration exists, open the casing and check the cause of the same
123
Marine Boiler Burner and Combustion – Combustion Air
Combustion Air: Fuel/ Air Ratio
Burner air-fuel ratio plays a critical role in achieving maximum efficiency out of
fuel-fired process heating systems such as furnaces, ovens, heaters, and
boilers.
If the amount of air supplied is less than required, the burner will run “rich”
i.e. not all fuel will burn inside the furnace. This will result in soot deposits on
the heat transfer surface, which reduces the overall efficiency.
If the amount of air is more than required, all the fuel will not be burnt,
leading to reduction in the efficiency.
Most high temperature direct-fired furnaces, radiant tubes, and boilers

operate with about 10% - 20% excess combustion air at high firing rate for
efficient combustion and to avoid building up of soot deposits on heat transfer
surfaces and inside radiant tubes.
124
The combustion air system supplies air to the burner according to the
demands of the control system. The draft loss of the burner air register is
measured by a differential pressure transmitter that converts the signal to flow
signal, which is used by the control system for automatic air/oil ratio control.
A directly driven centrifugal fan supplies the combustion air. The fan is
mounted on a common bed frame with the motor, inlet vanes, and servo-drive
unit.
The fan impeller inside the spiral housing is mounted directly on the motor
shaft. The air-flow to the burner is regulated by inlet vanes mounted on the
fan suction side.
Multi blade inlet vanes are installed in the passage of air near the burner,
which is normally regulated by a servo-driven unit comprising of an air cylinder
and an I/P positioner. A silencer can be mounted on the fan suction side.
125
Points to be noted when setting the air fuel ratio:
• The temperature of the combustion products as they leave the furnace
• The percentage of excess air or oxygen in flue gases, at which, the furnace
now operates
• The percentage of excess air or oxygen in flue gases, at which, the furnace
can operate
• The air/fuel ratio to be readjusted in order to achieve efficient combustion

with change in grade of fuel
• Since atomization by air has an effect on the excess ratio, the air fuel ratio
may need to be changed for Inert gas system operation
126
In the era of slow steaming and strict emission restrictions for ships, meeting
steam demands on board requires considering important factors such as
reduction of energy use and environmental impact.
For a ship professional, understanding the basics of marine boiler such as

construction and design is as vital as knowing the operation and
troubleshooting.
As the boiler efficiency greatly depends on the type of boiler, design and
system arrangement, it is imperative to know the factors that affect the overall
boiler operation in both short and long term.
If you have questions regarding this eBook or any topics mentioned herein,
send us a mail at
info@marineinsight.com
or post at
http://forums.marineinsight.com
127
Exclusive eBooks for Professional Seafarers
CLICK HERE TO KNOW MORE
“The eBooks published by Marine Insight are “Having worked as a Service Technician with MAN “Dry docking is by far the most tedious job I
proving quintessential in training seafarers B&W, I know the amount of efforts and precision it have come across on ships. Though it is
and further enlightening those who are takes to carry out an errorless overhauling of supposed to be known as the best learning
already in tanker trade. The Tricks of the generators on ships. As an expert who works on experience for mariners, it is important that
trade and Expert’s tips provided in this eBook marine engines, I recommend to use a guide like this you are well prepared for the job. If you want
will be guiding officers and crew towards which would assist you through the lengthy to a get a general overview of what exactly is
carrying out operations on board tankers procedure of generator d’card.” on A Step-By-Step done in dry docks and how the whole
efficiently and safely.” on The Ultimate Guide Guide to Overhauling Generators on Ships – operation is performed the this guide will
to Cargo Operations for Tankers – Capt. Musab.O.Karabulut, Technical inspector, AB surely help you a lot.” on A Guide to Master
Swapnil Hemchandra Dhamankar, Marine International Marine Services ; Previous- Service Dry Dock Operations - Hemant Rai, Second
Superintendent – Corporate Compliance , technician, Man B&W Engineer, Dynacom Tankers Management Ltd.
Fleet Management
© Marine Insight 2015 - All Rights Reserved www.marineinsight.com

Boiler Construction Part-1

Transféré par

Informations du document

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Boiler Construction Part-1

Transféré par

Droits d'auteur :

Formats disponibles

MARINE BOILER SERIES: PART 1

A Guide to Boiler Construction

Publication date: April 2015

Published by: Marine Insight

Graphic Design: Anish Wankhede

WATER TUBE BOILER

Considering their functionality, the

and extreme temperature with minimum heat loss to the surroundings.

Principle of Working: The marine boiler works on a simple principle of change

Smoke Tube Boiler

Horizontal Smoke Tube Boiler

Water Tube Boiler

Water Tube Boiler

the superheated steam from the boiler

The main features of water tube boilers are

• Forced, induced and balanced draft provisions help to improve combustion

• Higher thermal efficiency levels

• High pressure ratings

• Better quality of steam

• Suitable for large capacity system

Exhaust Gas Boiler

A composite boiler can be a water

Difference Between Smoke and Water Tube Boilers

High thermal stresses Low thermal stresses

Less efficient Highly efficient

Large diameter tube Small diameter tube

Heavy in weight Light in weight for same capacity

Risk of explosion is less Risk of explosion is high

BOILER EXTERNAL MOUNTINGS

The two safety valves are set at different

The stop valves are not meant

It is important to open the

Main Steam Valve

Bypass valve: This valve is installed in high-pressure boilers to equalize the

The vent valve should positively be opened when the

The discharge of the vent is generally provided with

at least 50mm above the point of overheating of the boiler.

As it is an inspection glass and prone to breaking, gauge

Other Notable Mountings:

Boiler Internal Mountings

Attemparator Steam Outlet

Cyclone Separator: Cyclone separator is similar to the filter, which is used to

Baffle Plates: Baffle plates are placed

Chemical Dosing and Feed Water Pipe

Problems in Boiler Mountings

Problems in gauge glass:

Problems in safety valves easing gear:

Problems in manhole doors:

Leaking manhole doors: The major problem with the

Maintenance of Boiler Mountings

• The boiler comprises of different types of valves fitted as boiler mountings

• The best and safest way to

• Overhauling of the complete

• Lap the valve and seat if required

• Check the trueness of the valve stem

• Renew the joint between the bonnet and the body

Maintenance of gauge glass:

A damaged fitting should be renewed or repaired immediately. Gauge glasses

• Any abnormal water level must be investigated as soon as it is observed,

Gauge glass blow down procedure:

• Close the drain cock and open the water cock

remedial action should be taken as soon as possible

Boiler Gauge Glass

• Close the drain cock and open the steam cock