Boiler Operator’s Guide, Fifth Edition
By Ray Wohlfarth and Anthony L Kohan
Contents:
Preface
Abbreviations and Symbols
Chapter 1 Boiler Systems, Classifications, and Fundamental
Operating Practices
Questions and Answers
Chapter 2 Firetube Boilers
Questions and Answers
Chapter 3 Watertube Boilers
Questions and Answers
Chapter 4 Electric and Special Application Boilers
Questions and Answers
Chapter 5 Nuclear Power Plant Steam Generators
Questions and Answers
Chapter 6 Material Structure, Required Code Material, and
Specifications
Questions and Answers
Chapter 7 Fabrication by Welding and NDT
Questions and Answers
Chapter 8 Material Testing, Stresses, and Service Effects
Questions and Answers
Chapter 9 Code Strength, Stress, and Allowable Pressure
Calculations
Questions and Answers
Chapter 10 Boiler Connections, Appurtenances, and Controls
Questions and Answers
Chapter 11 Combustion, Burners, Controls, and Flame Safeguard
Systems
Questions and Answers
Chapter 12 Boiler Auxiliaries and External Water Treatment
Equipment
Questions and Answers
Chapter 13 Boiler Water Problems and Treatment
Questions and Answers
Chapter 14 In-Service Problems, Inspection, Maintenance, and
Repairs
Questions and Answers
Chapter 15 Boiler Plant Training, Performance, and Efficiency
Monitoring
Questions and Answers
Appendix 1 Terminology and Definitions
Appendix 2 Water Treatment Tables
Appendix 3 Observing Boiler Safety Rules
Appendix 4 Professional Organizations
Appendix 5 Jurisdictions
Appendix 6 Unit Conversions
Appendix 7 Steam Tables
Appendix 8 Bibliography
Index
Preface
This book has been widely used by boiler personnel all over the world. From the classroom to the control room of any plant, it is an excellent reference for the boiler industry.
This fifth edition has been revised to include requirements of the latest codes of the American Society of Mechanical Engineers, the National Board of Boiler and Pressure Vessel Inspectors, and other national professional organizations. In addition, recent technological developments in the boiler industry have been included. Among the boilers with new technology are condensing boilers, hybrid boilers, solar heating boilers, and solar power generation boilers.
A list of professional organizations related to the boiler industry has been added to the book. The organizations’ contact information is included.
The jurisdictions that have operating engineer licensing laws have been updated. Also, the jurisdictions that have boiler and pressure vessel inspection laws have been completely revised. The contact information for the boiler inspection departments of states and major cities of the United States and provinces and territories of Canada has been added.
Also included in this fifth edition is an appendix showing unit conversions, which will come in handy when performing math calculations.
Extreme care was taken in revising the book. It covers the complete life cycle of the boiler, from design to repair, irrespective of the size of the plant. One chapter has been devoted to nuclear power plant generators, which are also designed under the ASME Boiler and Pressure Vessel Code.
CHAPTER 1
Boiler Systems, Classifications, and Fundamental Operating Practices:
Modern Operation and Responsibilities:
Boiler plant operation, maintenance, and inspection requires the services of trained technical people because of the growth and technological development in new materials, metallurgical principles on why materials fail, welding in joining boiler components and in repairs, sensor development which permits more automatic control, and finally the application of computers in tracking boiler operations and conditions.
Boilers are used at many different pressures and temperatures with large variations in output and different fuel-burning systems. Designers and fabricators apply heat transfer principles to design a boiler system but must also have broad technical skills in fluid mechanics, metallurgy, strength of materials to resist stress, burners, controls, and safety devices for the boiler system, or as stipulated by Codes and approval bodies.
The skill and knowledge required of operators may vary because installations range from simple heating systems to integrated process and utility boiler systems. Operating controls can vary from manual to semiautomatic to full automatic. The trend is to automatic operation.
However, experienced operators always study the boiler plant layout so that the components, auxiliaries, controls, piping, and possible emergency procedures to follow are thoroughly understood. The study should include a review of the fuel, air, water and steam, and fuel-gas loops, and the assigned limitations each may have in operation.
Operators must be familiar with modern boiler controls that are based on an integrated system involving controlling:
- Load flow for heat, process use, or electric power generation.
- Fuel flow and its efficient burning.
- Airflow to support proper and efficient combustion.
- Water and steam flows to follow load.
- Exhaust flow of products of combustion.
The highly automated plant requires the knowledge of how the system works to produce the desired results, and what to do to make it perform according to design. Manual operation may still be required under emergency conditions, which is why a knowledge of the different “loops” of a boiler system will assist the operator to restore conditions to normal much faster. With the growing use of computers, if a boiler system is out of limits, skilled personnel must trace through the system to see if the problem is in the instruments or out-of-calibration actuators or if a component of the system has had an electrical or mechanical breakdown.