Professional Documents
Culture Documents
3.1 Introduction
An overview of boiler regulations, with an evaluation of fuel types and comparisons.
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3.2 Shell Boilers
Overview of the different types of shell boiler with layouts, heat and steam release considerations plus
pressure and output limitations.
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3.3 Water-tube Boilers
Description of water tube boilers including operation, types and benefits; also, a brief synopsis on how they
are applied to combined heat and power generation.
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3.4 Miscellaneous Boiler Types, Economisers and Superheaters
An explanation of specialist boiler types and other specialist features.
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3.5 Boiler Ratings
This Module explains the three most commonly used boiler ratings: The From and at rating for
evaporation, the kW rating for heat output, and boiler horsepower.
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3.6 Boiler Efficiency and Combustion
A broad overview of the combustion process, including burner types and controls, and heat output and
losses.
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3.7 Boiler Fittings and Mountings
An overview of the necessary fittings, accessories and controls for a boiler from nameplates and safety
valves to gauge glasses and level controls.
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3.8 Steam Headers and Off-takes
This Module looks at steam header arrangements and other design considerations necessary for efficient
warm-up, good steam quality and proper steam distribution from the boiler house.
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3.9 Water Treatment, Storage and Blowdown for Steam Boilers
A look at the chemistry of water supplies including hardness and pH values.
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3.10 Water for the Boiler
A steam boiler plant must operate safely, with maximum combustion and heat transfer efficiency. To help
achieve this and a long, low-maintenance life, the boiler water can be chemically treated.
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3.11 The Feedtank and Feedwater Conditioning
All aspects of the design, construction and operation of feedtanks and semi-deaerators, including
calculations.
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3.12 Controlling TDS in the Boiler Water
The need to measure and control the total dissolved solids (TDS) in the boiler water boiler water, and the
methods used to do so, including closed loop electronic control with conductivity sensors.
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3.13 Heat Recovery from Boiler Blowdown (TDS control only)
Boiler water is blown down to control the amount of total dissolved solids (TDS) in the boiler. This water is
pressurised, hot and dirty, creating large volumes of flash steam and possible disposal problems. A heat
recovery system can reclaim large amounts of energy during this essential process.
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3.14 Bottom Blowdown
Factors surrounding the removal of suspended solids from the boiler, including valves, piping and
blowdown vessels, with calculations.
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3.15 Water Levels in Steam Boilers
The level of water in a steam boiler must be carefully controlled, to ensure good quality steam is produced
safely, efficiently and at the correct pressure.
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3.16 Methods of Detecting Water Level in Steam Boilers
The application of level controls and alarms, plus an overview of different level detection methods,
including float-type controls, conductivity probes and capacitance devices.
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3.17 Automatic Level Control Systems
A detailed explanation of on/off, modulating, two and three element automatic level control, with a
comparison of pros and cons.
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3.18 Water Level Alarms
The function of high and low level alarms. Low-level alarms will draw attention to low boiler water level
and, if required, shut down the boiler. High-level alarms protect plant and processes.
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3.19 Installation of Level Controls
The pros and cons of direct versus externally mounted level controls.
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3.20 Testing Requirements in the Boiler House
Requirements for regular testing will vary according to national regulations, and the type of equipment
installed.
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3.21 Pressurised Deaerators
The need to remove gases from boiler feedwater and the operation of a pressurised deaerator, plus
calculations.
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3.22 Steam Accumulators
A complete overview of the need for steam storage to meet peak load demands in specific industries,
including the design, construction and operation of a steam accumulator, with calculations.
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Flowmetering
this affects a valves controlling influence. The importance of positioners is discussed with regard to what
they do and why they are required for many applications.
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6.7 Controllers and Sensors
Controllers and sensors are important parts of the control system; without information from the sensor, the
controller cannot make a decision and instruct the valve to move. This Module briefly discusses the
different types of controllers and sensors available and how they operate. A brief explanation of digital and
analogue control signals is also given.
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Control Applications
Safety Valves
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9.2 Types of Safety Valve
A full explanation of the many different types of safety valves available, including operation, materials of
construction and accessories.
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9.3 Safety Valve Selection
Choosing and commissioning the correct safety valve, including selection considerations, setting, sealing,
positioning and the effects of backpressure.
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9.4 Safety Valve Sizing
An in-depth study of the sizing process for a range of applications, including sizing equations for AD
Merkblatt, DIN , TRD, ASME, API, BS6759 and others. Covers more complex issues such as two-phase
flow and superheat.
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9.5 Safety Valve Installation
Important installation advice, including handling, plant conditions, pipework configuration, markings and
noise considerations.
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9.6 Alternative Plant Protection Devices and Terminology
Other methods of relieving excess pressure explained; plus a useful terminology section.
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Steam Distribution
Selection tables and advice on trap selection for a range of different processes are included in this Module,
including heat exchangers, radiant panels, unit heaters, air heater batteries and overhead pipe coils.
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11.11 Selecting Steam Traps - Steam Mains; Tanks and Vats; Pressure Reducing Valves
Selection tables and advice on trap selection for different types of steam mains, headers and off-takes are
included in this Module, together with process vats and pressure reducing valve stations.
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11.12 Air Venting Theory
The presence of air has a devastating effect on steam systems and processes. The basic theory of air
venting is explained in this Module, plus advice on air vent location.
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11.13 Air Venting Applications
Some of the many different applications for air vents are described in this Module, including steam mains,
bypasses, jacketed vessels and rotating cylinders. Other issues such as venting large volumes of air,
group air venting and the substitution of thermostatic steam traps are also considered.
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11.14 Testing and Maintenance of Steam Traps
Indiscriminate maintenance of steam traps wastes money. This Module considers a planned approach to
steam trap testing and maintenance, with recommended methods and equipment.
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11.15 Energy Losses in Steam Traps
A large amount of inaccurate and misleading information has been written on this subject. This Module
gives clear, accurate information regarding the energy consumption of different trap types.
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Pipeline Ancillaries
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12.2 Isolation Valves - Rotary Movement
Isolation valves are used for diverting process media, facilitating maintenance, equipment removal and
shutdown. The operation, application and construction of rotary movement (quarter turn) valves, including
ball valves and butterfly valves, are covered in this module.
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12.3 Check Valves
Check (non-return) valves are installed in pipelines to allow flow in one direction only; helping to protect
equipment and processes. The operation, benefits, applications and selection of different designs,
including lift, disc, swing and wafer check valves are explained in this module.
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12.4 Strainers
Strainers arrest pipeline debris such as scale, rust, jointing compound and weld metal in pipelines,
protecting equipment and processes. This module considers the range of strainer and filter types in use
and how to size and select them for different applications.
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12.5 Separators
Wet steam is a major concern in a steam system as it can cause process and maintenance problems,
including lower productivity, erosion and corrosion. Separators are designed to efficiently remove the
moisture from steam flow. The application and selection of different types are considered here.
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12.6 Gauges, Sight Glasses, Vacuum Breakers
These small items of equipment have a variety of important applications throughout steam systems and
process equipment. The different types available are studied in this module.
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Condensate Removal
Condensate Recovery
Desuperheating
Equations
16.1 Equations
This Module lists in order of appearance all equations used throughout The Steam and Condensate Loop.
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