AMERICAN TECHNICAL PUBLISHERS ORLAND PARK, ILLINOIS
Frederick M. Steingress Daryl R. Walker
Low 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: James R. Hein
Cover Design: Sarah E. Kaducak Art Supervisor: Sarah E. Kaducak Illustration/Layout: Richard O. Davis Nick G. Doornbos Nick W. Basham Digital Media Manager: Adam T. Schuldt Digital Resources: Robert E. Stickley
Circuit Setter is a registered trademark of Fluid Handling LLC. Leadership in Energy and Environmental Design, LEED, Green Building Rating System, and U.S. Green Building Council are either registered trademarks or trademarks of the U.S. Green Building Council. National Electric Code and NEC are trademarks of the National Fire Protection Association, Inc., Quincy, MA, 02169. Teflon is a trademark of E. I. Du Pont de Nemours & Company. Thermoflo is a trademark of Fluid Handling, LLC. Triple Duty is a registered trademark of Bell & Gossett Company. QuickLinks, Quick Quiz, Quick Quizzes, and Master Math are trademarks of American Technical Publishers.
© 2019 by American Technical Publishers
5 6 7 8 9 – 19 – 9 8 7 6 5 4 3 2 1 Printed in the United States of America ISBN 978-0-8269-4372-9 This book is printed on recycled paper.
The author and publisher are grateful for the support provided by Cleaver-Brooks in the development of Low Pressure Boilers.
Technical information and assistance was provided by the following companies and organizations: Bacharach, Inc. Carrier Corporation CH2O Cleaver-Brooks Crown Boiler Co. Dunkirk Dwyer Instruments, Inc. Fireye, Inc. Fluke Corporation Fred Hutchinson Cancer Research Center The Fulton Companies Hach Company, USA Honeywell International Inc. ITT Bell & Gossett Jenkins Bros. Kewanee Boiler Manufacturing Co., Inc. Lab Safety Supply, Inc.
Parker Boiler Co. Peerless Boilers RESOL R.W. Beckett Corp. Smithsonian Institution Spirax-Sarco, Inc. Taco, Inc. The Trane Company University of Wisconsin – Parkside Water Furnace Inc. Watts Regulator Company Watts Water Technologies, Inc. Weil-McLain Xylem, Inc. Yellow Jacket Div., Ritchie Engineering Company, Inc. York International Corp.
Boiler Operation Principles
2
SECTION 1.1 — Boilers in Industry . . . . . . . . . . . . . . . . . . . . 3 SECTION 1.2 — Boiler Operation Theory . . . . . . . . . . . . . . . . 4 SECTION 1.3 — Boiler Systems . . . . . . . . . . . . . . . . . . . . . 19 SECTION 1.4 — Boiler Design and Construction . . . . . . . . . . 21
Steam Boiler Fittings
36
SECTION 2.1 — Safety Valves . . . . . . . . . . . . . . . . . . . . . . . 37 SECTION 2.2 — Steam Pressure Gauges . . . . . . . . . . . . . . . 44 SECTION 2.3 — Water Columns . . . . . . . . . . . . . . . . . . . . . 49 SECTION 2.4 — Blowdown Valves . . . . . . . . . . . . . . . . . . . . 53 SECTION 2.5 — Boiler Vents . . . . . . . . . . . . . . . . . . . . . . . . 58 SECTION 2.6 — Pressure Controls . . . . . . . . . . . . . . . . . . . 61 SECTION 2.7 — Heat Exchangers . . . . . . . . . . . . . . . . . . . . 66
Steam Boiler Feedwater Systems
70
SECTION 3.1 — Feedwater Accessories. . . . . . . . . . . . . . . . 71 SECTION 3.2 — Makeup Water Systems . . . . . . . . . . . . . . . . 77 SECTION 3.3 — Feedwater Regulators. . . . . . . . . . . . . . . . . 80 SECTION 3.4 — Low Water Fuel Cutoffs . . . . . . . . . . . . . . . . 83 SECTION 3.5 — Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Steam Systems
98
SECTION 4.1 — Steam Distribution . . . . . . . . . . . . . . . . . . . 99 SECTION 4.2 — Steam Traps and Strainers. . . . . . . . . . . . . .106
Fuel Systems
116
SECTION 5.1 — Gas Systems . . . . . . . . . . . . . . . . . . . . . . .117 SECTION 5.2 — Fuel Oil Systems . . . . . . . . . . . . . . . . . . . .123 SECTION 5.3 — Combustion Controls . . . . . . . . . . . . . . . . .140 SECTION 5.4 — Air Pollution . . . . . . . . . . . . . . . . . . . . . . .154
Draft Systems
160
SECTION 6.1 — Draft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161 SECTION 6.2 — Draft Control . . . . . . . . . . . . . . . . . . . . . . .170
Boiler Water Treatment
174
SECTION 7.1 — Boiler Water Conditions . . . . . . . . . . . . . . .175 SECTION 7.2 — Boiler Water Analysis . . . . . . . . . . . . . . . . .182 SECTION 7.3 — Boiler Water Treatment . . . . . . . . . . . . . . . .186
Boiler Operation Procedures
200
SECTION 8.1 —Taking Over a Shift . . . . . . . . . . . . . . . . . . .201 SECTION 8.2 — Startup and Shutdown . . . . . . . . . . . . . . . .207 SECTION 8.3 — Maintenance . . . . . . . . . . . . . . . . . . . . . . .212 SECTION 8.4 — Handling Boiler Conditions . . . . . . . . . . . . .223
Hot Water Boilers and Fittings
230
SECTION 9.1 — Hot Water Heating Systems . . . . . . . . . . . . .231 SECTION 9.2 — Hot Water Boilers . . . . . . . . . . . . . . . . . . . .236 SECTION 9.3 — Burners and Igniters. . . . . . . . . . . . . . . . . .245 SECTION 9.4 — Hot Water Boiler Fittings . . . . . . . . . . . . . . .248
Hot Water Boiler Accessories and Piping Systems
262
SECTION 10.1 — Hot Water Boiler Accessories. . . . . . . . . . .263 SECTION 10.2 — Hot Water System Valves . . . . . . . . . . . . . .282 SECTION 10.3 — Piping Systems . . . . . . . . . . . . . . . . . . . .290
Cooling Systems
298
SECTION 11.1 — Cooling System Principles. . . . . . . . . . . . .299 SECTION 11.2 — Cooling Systems . . . . . . . . . . . . . . . . . . .307 SECTION 11.3 — Refrigerants. . . . . . . . . . . . . . . . . . . . . . .328
Boiler Operation Safety
340
SECTION 12.1 — Regulatory Agencies and Standards Organizations. . . . . . . . . . .341 SECTION 12.2 — Boiler Room Safety Programs . . . . . . . . . .346 SECTION 12.3 — Personal Protective Equipment (PPE) . . . . .360 SECTION 12.4 — Electrical Safety . . . . . . . . . . . . . . . . . . . .364 SECTION 12.5 — General Safety Programs. . . . . . . . . . . . . .367
Boiler Operator Licensing
372
SECTION 13.1 — Boiler Operation Careers . . . . . . . . . . . . . .373 SECTION 13.2 — Boiler Operator Licenses. . . . . . . . . . . . . .375 SECTION 13.3 — Sample Licensing Examination Questions . . .378
Answer Key
389
Appendix 391 Glossary 409 Glossary of Historical Terms
433
Index 439
• Quick Quizzes™ • Illustrated Glossary • Flash Cards • Sample Licensing Exams • Boiler Fitting Identification Simulation • Master Math™ Applications • Historical Boiler Terms • Media Library • ATPeResources
Low Pressure Boilers provides information on the safe and efficient operation of low pressure steam boilers, hot water heating systems, cooling systems, and related equipment. The textbook can be used as a study guide for boiler operator or facility operating engineer licensing. It can also be used as an introduction to stationary engineering or as a reference book for upgrading skills. The extensive illustrations show equipment details and sequential operating procedures for common boiler operator duties. Photographs from actual job sites and from leading equipment manufacturers are included to illustrate what a boiler operator may see on the job. This new edition has been enhanced with updated coverage of hot water heating systems, hot water boilers, burners, igniters, and hot water heating system accessories and piping systems. Energy efficiency and environmental issues are emphasized throughout the textbook with extensive material on condensing boilers, blowdown procedures, heat exchanger principles, boiler emissions requirements, refrigerant management, environmental concerns with refrigerants, and blowdown temperature control and heat recovery. Enhanced coverage of the U.S. Green Building CouncilŽ and their Leadership in Energy and Environmental Design™ (LEEDŽ) green building program provides useful information on leading environmental improvement activities. A new glossary of historical terms has been added as a reference to illustrate common terminology and technology from the past.
Low Pressure Boilers includes many features that enhance learning. This edition includes detailed equipment photos, warnings, tech facts, step-by-step procedures, and application photos.
Check Points provide learning review for each section Chapter Sections identify main topics covered Equipment Photos identify common types of equipment used in boiler systems Warnings are placed in context to warn operators of potential risks
Application Photos supplement text descriptions Step-by-Step Procedures describe the proper methods of performing common tasks
Tech Facts provide supplemental facts related to the topics discussed
Low 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™ Access 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 chapter, 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 textbook illustrations • Flash Cards that provide a self-study/review of ASME symbols and of common terms and their definitions • Sample Licensing Exams that provide opportunities to practice taking licensing exams • Boiler Fittings Identification Simulation that allows learners to interactively test and troubleshoot boiler equipment and related systems • Master Math™ Applications that provide interactive questions and math problems involving calculations related to boiler operation • Historical Boiler Terms that serve as references to field terms used in the past, with selected terms linked to textbook illustrations • Media Library that consists of videos and animations that reinforce textbook content • ATPeResources.com, which provides access to additional online resources that support continued learning To obtain information on other related training material, visit the American Technical Publishers website at www.atplearning.com. The Publisher