Frederick M. Steingress Harold J. Frost Daryl R. Walker
High Pressure Boilers contains procedures commonly practiced in industry and the trade. Specific procedures vary with each task and must be performed by a qualified person. For maximum safety, always refer to specific manufacturer recommendations, insurance regulations, specific job site and plant procedures, applicable federal, state, and local regulations, and any authority having jurisdiction. The material contained herein is intended to be an educational resource for the user. American Technical Publishers assumes no responsibility or liability in connection with this material or its use by any individual or organization.
American Technical Publishers Editorial Staff Editor in Chief: Jonathan F. Gosse Vice President — Editorial Peter A. Zurlis Assistant Production Manager: Nicole D. Bigos Technical Editor: Eric F. Borreson Supervising Copy Editor: Catherine A. Mini Copy Editor: Jeana M. Platz Editorial Assistant: Erin E. Magee Cover Design: Richard O. Davis
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© 2019 by American Technical Publishers All rights reserved 6 7 8 9 – 19 – 9 8 7 6 5 4 3 2 1 Printed in the United States of America ISBN 978-0-8269-4331-6
This book is printed on recycled paper.
ACKNOWLEDGMENTS The authors and publisher are grateful for the photographs and technical information provided by the following companies and organizations: ABB Inc., Drives & Power Electronics ASI Robicon Aurora Pump Babcock and Wilcox Co. CH20 Cleaver-Brooks Dwyer Instruments, Inc. Eastern Illinois University Renewable Energy Center Fireye, Inc. Fluke Corporation Fred Hutchinson Cancer Research Center Hach Company, USA
Jenkins Bros. Lab Safety Supply, Inc. McDonnell & Miller The Permutit Co., Inc. Port of Seattle Quad/Graphics, Inc. Rosemount Analytical Saftronics Inc. Sarco Co., Inc. Teledyne Farris Engineering TSI Incorporated
Technical review assistance: Stephen F. Connor Cleaver-Brooks Byron D. Nichols President, Thermal System Training, LLC American Society of Power Engineers, Board of Directors
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CONTENTS CHAPTER 1 — STEAM BOILERS______________________________________ 2 SECTION 1.1 — STEAM BOILER TYPES __________________________________ 3 SECTION 1.2 — BOILER CONSTRUCTION ______________________________ 15 SECTION 1.3 — USES OF STEAM_______________________________________ 20 CHAPTER 1 EXAM __________________________________________________ 23
CHAPTER 2 — BOILER SYSTEMS____________________________________ 28 SECTION 2.1 — STEAM SYSTEMS_______________________________________ 29 SECTION 2.2 — FEEDWATER SYSTEMS__________________________________ 30 SECTION 2.3 — FUEL SYSTEMS________________________________________ 33 SECTION 2.4 — DRAFT SYSTEMS_______________________________________ 37 SECTION 2.5 — INSTRUMENTATION AND CONTROL SYSTEMS___________ 40 CHAPTER 2 EXAM___________________________________________________ 43
CHAPTER 3 — STEAM BOILER FITTINGS____________________________ 48 SECTION 3.1 — FITTINGS FOR SAFETY_________________________________ 49 SECTION 3.2 — FITTINGS FOR OPERATION_____________________________ 55 CHAPTER 3 EXAM___________________________________________________ 63
CHAPTER 4 — STEAM SYSTEMS____________________________________ 68 SECTION 4.1 — SUPERHEATERS AND DESUPERHEATERS_________________ 69 SECTION 4.2 — STEAM TURBINES_____________________________________ 74 SECTION 4.3 — STEAM TRAPS_________________________________________ 78 SECTION 4.4 — CONDENSATE RETURN________________________________ 83 CHAPTER 4 EXAM___________________________________________________ 87
CHAPTER 5 — FEEDWATER SYSTEMS_______________________________ 92 SECTION 5.1 — WATER LEVEL CONTROL _______________________________ 93 SECTION 5.2 — FEEDWATER HEATERS ________________________________ 102 SECTION 5.3 — FEEDWATER PUMPS AND LINES________________________ 106 CHAPTER 5 EXAM__________________________________________________ 113 iv
CONTENTS CHAPTER 6 — WATER TREATMENT_________________________________ 118 SECTION 6.1 — BOILER WATER CONDITIONS AND ANALYSIS___________ SECTION 6.2 — EXTERNAL BOILER WATER TREATMENT________________ SECTION 6.3 — INTERNAL BOILER WATER TREATMENT ________________ CHAPTER 6 EXAM__________________________________________________
119 126 132 143
CHAPTER 7 — COMBUSTION EQUIPMENT___________________________ 148 SECTION 7.1 — FUEL OIL SYSTEMS____________________________________ SECTION 7.2 — NATURAL GAS SYSTEMS______________________________ SECTION 7.3 — COAL SYSTEMS_______________________________________ CHAPTER 7 EXAM__________________________________________________
149 157 163 169
CHAPTER 8 — FUELS AND COMBUSTION___________________________ 174 SECTION 8.1 — BOILER FUELS________________________________________ 175 SECTION 8.2 — COMBUSTION OF FUELS______________________________ 181 CHAPTER 8 EXAM__________________________________________________ 187
CHAPTER 9 — COMBUSTION AND BOILER CONTROLS_______________192 SECTION 9.1 — BURNER MANAGEMENT SYSTEMS______________________ 193 SECTION 9.2 — COMBUSTION CONTROL SYSTEMS____________________ 197 CHAPTER 9 EXAM__________________________________________________ 209
CHAPTER 10 — DRAFT SYSTEMS___________________________________ 214 SECTION 10.1 — DRAFT TYPES_______________________________________ 215 SECTION 10.2 — DRAFT DESIGN AND CONTROL_______________________ 218 SECTION 10.3 — ENVIRONMENTAL REGULATIONS_____________________ 224 CHAPTER 10 EXAM_________________________________________________ 233
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CONTENTS CHAPTER 11 — INSTRUMENTATION AND CONTROL SYSTEMS_______ 238 SECTION 11.1 — BOILER INSTRUMENTATION___________________________ 239 SECTION 11.2 — BOILER CONTROL SYSTEMS__________________________ 256 CHAPTER 11 EXAM_________________________________________________ 265
CHAPTER 12 — STEAM BOILER OPERATION__________________________ 270 SECTION 12.1 — OPERATOR DUTIES AND RESPONSIBILITIES____________ 271 SECTION 12.2 — BOILER SAFETY CHECKS_____________________________ 280 SECTION 12.3 — BOILER MAINTENANCE AND INSPECTIONS____________ 286 SECTION 12.4 — BOILER ROOM SAFETY_______________________________ 291 SECTION 12.5 — BOILER OPTIMIZATION_______________________________ 298 CHAPTER 12 EXAM_________________________________________________ 307
CHAPTER 13 — LICENSING___________________________________________ 312 SECTION 13.1 — LICENSING__________________________________________ 313 EXAM 1____________________________________________________________ 319 EXAM 2____________________________________________________________ 325 EXAM 3____________________________________________________________ 331 EXAM 4____________________________________________________________ 337 EXAM 5____________________________________________________________ 343 EXAM 6____________________________________________________________ 351
CHAPTER 14 — Principles of Electricity_____________________________ online APPENDIX_________________________________________________________________ 359 GLOSSARY__________________________________________________________ 369 INDEX______________________________________________________________ 381
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INTRODUCTION High Pressure Boilers provides information on the safe and efficient operation of high pressure boilers and related equipment. The content and the format of the textbook are specifically designed for use in preparation for boiler operator or facility operator engineer licensing. The textbook can also be used as an introduction to stationary engineering or as a reference for upgrading skills. The extensive illustrations show equipment details and sequential operating procedures for common boiler operator duties. Photographs from industry and leading equipment manufacturers are included to illustrate what a boiler operator may see on the job. This new edition has been thoroughly updated with many energy efficiency and environmental topics emphasized throughout. Additional content on heat exchanger principles, boiler emissions requirements, and blowdown temperature control and heat recovery has been added. A new section on environmental regulations provides a summary of operating requirements. Tech tips and case studies are located throughout the textbook to enhance the content. Sample exams following each chapter are used to test for understanding of information presented in the chapter. Also, an appendix, glossary, and index are provided for easy reference. Questions to develop critical thinking skills are provided at the end of each section.
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FEATURES Checkpoint questions develop critical thinking skills. Illustrations highlight details of boiler systems and components.
Chapter sections divide the content into topical sections.
Tech tips provide information that supplements text content. Safety procedures are emphasized throughout. Lists are used throughout for concise coverage. Equipment cutaways enhance understanding of equipment operation.
Photographs depict examples from industry
Tables summarize complex content.
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LEARNER RESOURCES High Pressure Boilers includes access to online learner resources that reinforce content and enhance learning. These online resources can be accessed using either of the following methods: • Key ATPeResources.com/quicklinks into a web browser and enter QuickLinks™ code . • Use a Quick Response (QR) reader app to scan the QR code with a mobile device.
The online learner resources include the following: • Quick Quizzes™ that provide interactive questions for each section, with embedded links to highlighted content within the textbook and to the Illustrated Glossary • Illustrated Glossary (English/Español) that serves as a helpful reference to commonly used terms in both English and Spanish, with selected terms linked to illustrations • Flash Cards that provide a self-study/review of common terms and their definitions as well as provide recognition practice for HVAC, refrigeration, and DMM symbols • Master Math™ Applications that help learners prepare for a more advanced license • Sample Licensing Exams provide opportunities to practice taking a licensing exam • Boiler Operator Resources provide the learner with printable tables of supplemental information • Media Library that consists of videos and animations that reinforce textbook content • eResources.com, which provides access to additional online resources that support continued learning
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