CNTL 3401

Marine Processes & Systems:

Boiler Controls
 Marine Processes and Systems
In this section, we will discuss several marine processes and systems:
• Boiler (Steam Plant System) Controls
• Steam Turbine Controls
• Pump Control Systems
• Ballast Control Systems
• Heating Ventilation Air Conditioning (HVAC) Systems
 Boiler (Steam Plant System) Controls
• There are several systems involved with the efficient control of
industrial boilers used for steam production.
• The main systems used involve:
• Boiler Level Control
• Combustion Control
• Steam Temperature Control
• Furnace Pressure Control
 Boiler Level Controls
• In order for a boiler to operate safely and efficiently, there must be balances
existing between water input, heat added and the steam produced under
various load changes or demand for steam from the boiler.
• As steam demand increases, the mass of water inside the drum decreases
proportionally, and water feed rate must then be adjusted to bring the drum
level back to is required set point level.
• A decrease in demand results in an opposite response. Essentially, there is a
balance between water entering and leaving the boiler.
• Maintaining level in the boiler drum is critical to boiler operation:
• Too little water will expose boiler tubes and will cause heat stresses that
can rupture them.
• Too much water will cause large water droplets to carry over into the
steam discharge and can cause damage to equipment down-stream from
the boiler.
 Boiler Level Controls
• There are three basic drum level control systems used depending on the
size of the boiler being used. These are 1, 2, and 3 element drum level
control systems. With any of these types of level control systems, there
exists a problem whereby the level in the boiler drum basically responds
opposite to what you might expect.
• For example, when there is an increased steam demand from the boiler,
initially we would expect a decrease in level as steam exits the drum, then
feed-water would be added to bring the level back up. However, as steam
exits the boiler, steam pressure decreases inside the boiler and the level
momentarily increases as the heated water expands. This condition is called
swell.
• A decrease in demand causes the opposite effect. As steam demand
decreases there temporarily exists an increase in internal pressure which
compresses the water inside the boiler drum. This causes the water level to
drop (opposite to what you would expect since less steam is being used).
This condition is called shrinkage.
• Under both circumstances, there may be a balance between the mass of
water entering and the mass of steam leaving the drum, but level
indications are opposite. For small boilers, shrink and swell are temporary
conditions that will correct themselves after a short time period, but for
large boilers, the effects must be managed.
 Single Element Drum Level Control
• This is the simplest form of boiler drum level control system and is used on
small capacity boilers with fairly constant load demand.
• A basic feedback loop may be used in a single element system. Typically a
differential pressure level transmitter (closed tank, wet leg reference) will be
used to measure the level in the boiler drum.
• A level controller will adjust the boiler feed-water valve proportional to a
direct measurement of level.
• It is important to note that there is no relationship between the drum level
and the steam or feed-water flow in a single element level control.
• A disadvantage of this system is the system’s initial response to a load
change. The shrink and swell effect will have the opposite desired response
resulting in possibly inadequate control. Since the shrink and swell response
are only temporary conditions, levels will eventually be restored to its
proper value, however, there may be a large initial deviation from the
setpoint with every load change.
 Single Element Drum Level Control

Single Element Drum Level Control System.

From: http://instrumentationtools.com/drum-level-control-systems/
 Single Element Drum Level Control

Single Element Drum Level Control System. From:

http://instrumentationtools.com/feedforward-vs-feedback-control/
 Two Element Drum Level Control
• Since the steam demand affects the boiler drum level, we can use the
measurement of steam flow to more accurately control the flow of feed-
water into the boiler drum to minimize the shrink and swell effect.
• The level element is still present and compared to a set point within the
controller. The controller will in turn generate a corrective action to the
feed-water valve.
• The addition of the steam flow element (a mass flow rate signal) is give
immediate corrections to the feed-water demand in response to load
changes.
• The controller will calculate the required feed-water based on both signals
and associated constants and biases that match the feed-water flow rate
with the steam flow-rate, pound for pound.
• This control system is really a variation of a feedforward with feedback trim
control with steam being the feedforward signal and level as the feedback.
This arrangement will result in a much smoother level control in the drum.
• Feed-water pressure needs to remain constant to achieve smooth level
control.
 Two Element Drum Level Control

Two Element Drum Level Control System.

From: http://instrumentationtools.com/drum-level-control-
systems/
 Two Element Drum Level Control

Two Element Drum Level Control System – Feedforward with feedback trim.
From: http://instrumentationtools.com/feedforward-vs-feedback-control/
 Feedback Control vs. Feedforward – Level Control
To refresh your memory on feedback vs. feedforward, the following two
diagrams may be helpful.

Feedback Feedforward

From: http://instrumentationtools.com/feedforward-vs-feedback-control/
 Three Element Drum Level Control
• A three element drum level control system may be used with there are
more than one boiler, multiple boilers and/or variations in the feed-water
pressure.
• The need for a three element drum level control became evident as the
boiler operating pressure increased over the years. Likewise the cost of
building and installing large steam drums became very expensive.
Therefore, medium to high pressure boilers became the norm and size was
compromised due to cost. This meant that disturbances in the boiler had to
be addressed quickly due to the higher pressures and smaller physical size.
• A sophisticated feedforward, feedback and cascade combination was
implemented as a control strategy to quickly address any disturbances.
• In the three element control arrangement, a level element, steam flow
element and a feed-water flow element are used resulting in a much tighter
control strategy however much more difficult to control.
 Three Element Drum Level Control
• Of the three elements, the liquid level is the highest priority. It is important
to ensure that the water isn’t too high so that there is enough volume
above the water for steam production and not too low that the steam
generating tubes were lacking water supply.
• The feed-water flow rate is subject to change as the supply pressure
changes over time due to different sources of feed-water and the use of
multiple pumps.
• The amount of feed-water flow will directly impact the liquid level. For
example, if the liquid level becomes low, it is not sufficient enough to tell
the feed-water valve to open more without taking in consideration whether
the flow rate has dropped as well (or increased for that matter).
• The association of the liquid level and feed-water flow is an ideal application
for a cascade control strategy. The feed-water flow controller will adjust the
feed-water valve position to its set point immediately when a change in flow
is sense (even before a change is level is detected). The flow loop will be a
fast control loop and will be identified as the secondary or slave controller.
The level controller will be the primary or master controller and will adjust
the set point of the flow controller when a change in level is detected.
 Three Element Drum Level Control
• The third element of the system is the steam flow rate leaving the drum.
This will track the steam demand which is the most common disturbance to
the system.
• The steam flow rate will be a feedforward signal which can be used in one
of two ways:
• Added into the output of the level controller to adjust the feed-water
flow control loop set point (Example 1) or
• Added into the output of the feed-water flow control loop to directly
manipulate the boiler feed-water valve.
*Note: Some systems do not feed the steam flow signal forward directly.
The system may determine the difference between the outlet steam flow
and the feed-water flow. The difference can be used to adjust the set point
to the feed-water flow controller. The level controller will be used to
correct for any disturbances using the normal feedback control. (Example
2)
 Three Element Drum Level Control

Three Element Drum Level Control System.

From: http://instrumentationtools.com/drum-level-control-
systems/
 Example 1 - Three Element Drum Level Control

Three Element Boiler Drum Level Control System.

From: http://blog.opticontrols.com/archives/165
Example 2 - Three Element Drum Level Control
 When to use Cascade vs. Feedforward
In case the past example brought up some confusion between cascade and
feedforward, the following clarifications should alleviate any concerns:
Feedforward:
• Involves a measurement, prediction and action
• Feedforward controllers measures the disturbance, D, while it is still distant,
uses it to predict an impact on the PV, and compute preemptive actions.

Cascade:
• Cascade controls requires that an “early warning” secondary measured
process variable, PV2, be identified that is inside the primary measured
process variable, PV1.
• Uses two traditional PID controllers
 Boiler Combustion Controls
• The objectives for combustion control for a boiler is to balance the correct
amount of heat required to produce the steam demanded from the boiler,
quickly, efficiently and safely, while minimizing emissions into the
environment.
• The combustion control system must:
• provide proper heat release in accordance with steam demand.
• manage the sharing of load with other boilers operating at the same time.
• provide an optimal fuel to air mix that ensures complete combustion and high
efficiency.
• The control system must ensure a quick response in order to maintain a
quality steam supply to downstream processes. Boiler size, fuel type, and
combustion system design impact on how quickly a boiler can respond to
demand changes.
• Inefficient fuel combustion can present obvious effects. Incomplete
combustion of fuel can increase the risk of explosion and also produce
increased emissions from the stack. From an economical point of view, this
will also increase costs of operation as furnace efficiency is not optimal.
 Boiler Combustion Controls
• Ensuring complete combustion of fuel then is one of the main objectives of
combustion control.
• Complete combustion can be achieved by supplying more air (excess air)
than is theoretically required to completely burn the fuel added to the
combustion chamber.
• However, the system must not provide for too much excess air, as this will
carry heat up the stack and reduce boiler efficiency and increase fuel
consumption. (As a rule of thumb, 25% excess air will ensure complete
combustion).
• Combustion controls involve maintaining fuel and air mixtures into the
combustion chamber in correct proportion. For obvious safety reasons, fuel
is never added into the combustion chamber until adequate air flow has
been established and a purge cycle has been completed.
• On the other end of the combustion cycle, as fuel is reduced into the
combustion chamber, air flows are maintained at a higher level than
required to ensure all fuel has been completely burned.
Air flow must lead fuel flow on increased demand from a boiler,
and must lag fuel flow on decreased demand from the boiler.
 Boiler Combustion Controls
• It is the objective of the combustion control system to maintain the correct
portion of fuel and air while keeping burner efficiency as high as possible.
• Since the primary objective of the boiler is to provide the correct amount of
steam to downstream processes, the measurement of steam header
pressure is used as the “master” control signal for the combustion control
system.
• There are 4 main combustion control schemes:
1) Parallel Adjusted Non-Metering
2) Parallel Adjusted Full-Metering
3) Parallel Adjusted Full-Metering & Fuel Limiting
4) Oxygen Trim with Load Compensation or Combustion Analysis
Compensation
 Parallel Adjusted Non-Metering
• This is mainly used on institutional boilers where slow or moderate load changes
would be experienced.
• Fuel supply is usually standard (no-mix) fuel and the system must have tightly
calibrated ratio of fuel and air mixture.
• The fuel and air mixture ratio may be achieved by:
• Using a mechanical adjustment on the air damper and control valve linkage
(parallel jackshaft) that requires manual adjustment for any changes in
conditions
• By using a split range control system with fuel to air bias station. The signal
from the pressure controller is sent to both FCEs (fuel and air) however, the
proportions for each variable does not typically support efficient combustion.
Likewise the FCEs have a non-linear flow characteristic. To combat this
problem, the cams in the positioners of the FCEs will be adjusted in the field.
The bias station can be used to compensate for any discrepancies.
• Fuel and air flows are not measured (non-metered).
• A low air pressure switch may be used as an interlock to prevent excess fuel from
entering the chamber in the event of low air pressure.
Split Range - Parallel Adjusted Non-Metering
Manual Adjustment – Single Point Positioning System
 Parallel Adjusted Full-Metering

• In this arrangement, air and fuel flows are measured and sent to dedicated
controllers (Feedback control).
• The master controller (Steam) provides set point to air and fuel controllers
in a split-range (parallel) cascade form of control.
• Air and fuel controllers are secondary (slave) control loops to the primary
(master) control loop (steam).
• The secondary loops correct for any downstream fluctuation in air and fuel
flow with the primary controller simply calling for prescribed amounts of air
& fuel.
• For greater efficiency, a ratio adjustment device can be used on the air
supply signal to characterize the amount of air flow over the load range of
the system.
• This system does not take into consideration the phase difference (lead/lag)
of the air to fuel supply to the combustion chamber. Therefore it is best
suited to applications where slow to moderate load changes would be
experienced, such as, institutional boiler systems or industrial processes
with fairly constant loads.
Parallel Adjusted Full-Metering
 Parallel Adjusted Full-Metering & Fuel Limiting
In large capacity boiler systems, a constant fuel ratio must be maintained
under all load conditions. Therefore lead/lag relationships must be
compensated for by the control system. (Air must lead on increase/ lag
decrease).
 Parallel Adjusted Full-Metering & Fuel Limiting
• To ensure that the lead/lag relationship exists, selector relays FY101A and B are added. This
will ensure that when there is an increase in firing rate (steam requirement), the air flow
leads the fuel. If a decrease in firing rate occurs, the fuel will decrease first followed by the
air flow.
An example scenario is as follows:
1) PT1 output increases (steam pressure increase therefore need to cut back steam)
2) PIC 101 output decreases (Reverse Acting Controller) and each of the air and fuel selector
relays receive a new lower set point.
3) The low selector relay FY101A (fuel selector) will compare the new lower set point from
PIC 101 with the current air flow rate (which is currently higher than the new set point).
The lower value (which is the new set point from PIC) will be pass along to the fuel flow
controller FIC101. The FCV1 will close as a result to bring the flow rate closer to the new
lower setpoint. (FIC-101 is also a reverse acting controller since it has a positive error and
closes the FCV).
4) At the same time, the high selector relay FY101B will compare the same set point from PIC
101 and the fuel flow rate. In this case the fuel flow rate will be chosen as the highest
value and this will keep the air flowing from FCV 2.
5) FT 101 output decreases until FIC 101 error is zero. In the meantime, as the FT 101 is
lowered it will pass the lowering value through high select relay FY-101B to become a new
lower value for FIC 201. The air flow valve will begin to close as a result until it’s new set
point is reach. Eventually a point of equilibrium will be reached that matches the new set
point from PIC.
*This type of combustion control may be used on industrial processes with moderate to fast
demand changes from the boiler.
 Oxygen Trim with Load Compensation or
Combustion Analysis Compensation
• Oxygen trim can be used with any of the previous systems mentioned to
increase the efficiency of the fuel firing process.
• For complete combustion, the air supply system need only supply the exact
amount of air to burn the fuel. Any amount of air supply above this amount will
reduce efficiency by carrying heat out the stack with the flue gases.
• By monitoring the flue gases from the boiler, we can measure the amount of
excess oxygen with an oxygen analyzer which provides a measurement signal to
a controller (AIC).
• When load compensation is used, the set point to the controller is derived from
the master (steam) controller with a characterizing relay (produces an excess
oxygen set point relative to boiler load). This is used due to the non-linear nature
of excess oxygen to boiler load. The amount of excess oxygen varies inversely
with steam demand (low loads have higher excess oxygen).
• The output from the controller, with limiting and bias stations (adjusted to
different boiler requirements), provides an additional signal which is added to
the control signal from the air flow controller. The high-low limiter is used to
ensure the oxygen controller signal remains within a desired range (does not
exceed air flow signal).
• This signal then actuates the air flow damper thus providing the exact amount of
air to efficiently burn the fuel.
Oxygen Trim with Load Compensation or
Combustion Analysis Compensation
 Steam Temperature Control
• The purpose of the steam temperature control is to improve the thermal
efficiency of turbines and certain industrial processes which require fairly
constant steam temperatures. It also reduces the chance of condensate.
• Superheated steam reduces fluid friction and erosion of a turbine.
• Superheated steam is generated by passing steam from the boiler drum through
the superheater tubes. There can be one or two stage superheaters involved in a
typical boiler.
• Steam temperature is normally controlled by inserting a device called an
Attemperator or Desuperheater in between the two superheaters. This is a
device which cools the system by either directly spraying a fine mist of water
into the steam or by passing cooling water through a heat exchanger
arrangement.
• In a simple feedback control strategy, steam temperature exiting the boiler is
measured, providing feedback to a temperature controller. This manipulates a
control valve supplying cooling water to a Attemperator or Desuperheater. The
objective is to maintain a final output steam temperature at a constant value
with changing load on the boiler.
• More sophisticated control can be achieved through a cascade or feedforward
arrangement. An example of cascade control will be shown in the upcoming
slides.
 Steam Temperature Control - Simple Feedback Loop

©OptiControls
 Steam Temperature Control – Cascade Control

©OptiControls
 Furnace Pressure Control
• The objective of the furnace pressure control is to achieve a balance
between fuels entering the furnace and combustion gases exiting out the
flue.
• There will be a greater volume of gases exiting the furnace than entering as
a result of combustion and an increase in temperature, therefore an
increase in furnace pressure will result.
• If we can maintain furnace pressure at its design level, we can optimize
boiler performance for efficient heat transfer.
• There are four categories of pressure operation:
1) Natural Draft – Chimney Effect
• Hot gas will tend to rise up the chimney leaving a vacuum at the base of the
column.
• The vacuum will draw the combustion air into the furnace
• Control achieve through uptake dampers at outlet of boiler
2) Induced Draft – Fans draw air though a furnace
3) Forced Draft – Fans blow air through the furnace and up the stack
4) Balanced draft – Combined induced and forced draft
 Furnace Pressure Control

© Power Engineering Training Systems

 Furnace Pressure Control

©Applied Process Control Instrumentation, Jean Potvin

 B A

1
2

Simplified
Burner Control
Schematic
**Cams hold position
POST- even when timer motor
CONTACT PURGE IGNITE PILOT OPERATING PERIOD is de-energized.
PURGE
T1 Operating Control
T2 Timer switch opens and
Stopped timer resumes
T3 cycle. Upon
Here. **
T4 completion of
cycle, cams ready
T5 (Position 2) for next cycle
 Packaged Boiler Control System
Burner Control (Simplified)
Assuming all permissives/interlocks are satisfied and the main breaker is closed, closing of the
operating control contact and starting switch will initiate the burner start cycle:
a) The Master Relay (MR) energizes and the A contact will close while the B contact opens.
b) The timer motor starts via the T5 contact (in position 1), and timer drum starts rotating
which initiates the timing cycle.
c) T1 contact closes and starts fan motor to purge combustion chamber.
d) When the purge time is over, T2 contact closes and energizes ignition transformer
allowing the igniter to begin sparking.
e) After a short period of time, T3 contact closes and opens pilot valve and the pilot flame
will light from the igniter spark.
f) The Flame Detector operates as the pilot flame is detected. This will allow the FR contact
to close.
g) T4 contact closes opening the main burner fuel valve thus firing up the burner (if air
pressure (air flow) and flame detection is OK).
h) T2 and T3 contacts open de-energizing the ignition transformer and the pilot valve.
i) The T5 contact changes state (to position 2) and the timer motor stops. It is important to
remember that cam switches will hold their current position even when timer motor is
de-energized. The timer will start to increment again when motor is re-energized.

….Continued next slide

 Packaged Boiler Control System
Burner Control (Simplified)
j) The boiler continues to operate until operating control contact opens or
potentially one of the other switches open due to an alarm state.
k) The master relay de-energizes and the main burner valve shuts off cutting
off flame. The flame scanner no longer sees the flame and FR contact
reopens.
l) Once MR de-energizes, it’s B contact returns to close. Since T5 is still in
position 2 when B is now closed, the timer motor will resume timing cycle.
m) The fan motor continues to run since T1 is still closed until combustion
chamber is purged (Timer has completed its cycle)
n) T1 opens stopping fan motor
o) T5 also changes state at the end of the post-surge cycle and this will stop
the timer motor’s timing cycle. The boiler is now ready for the next start
up when all the permissives/interlocks are ready again (All 6 switches
return to closed).
**Keep in mind that many of the boiler control systems are now automated
through the use of PLC (Programmable Logic Controllers) and DCS (Distributed
Control Systems) with HMI (Human Machine Interface) capability. More info to
follow in the common slides.
Packaged Boiler Control System
 Packaged Boiler Control System – Burner Control
• In Canada, the Canadian Standards Association (CSA) oversees the safe
operation of gas or propane fired equipment. Consult CSA Standard B149.3
for more information.
• Some of the mandatory requirements for various heater and BMS (Burner
Management Systems) are as follows:
1) Mandatory Purging
2) Permissive Interlocks
3) Double Block and Bleed Systems
4) Pilot and Ignition Systems
5) Dedicated Flame Monitoring Systems
6) High/Low Pressure, Temperature and Flow Control
7) Combustion Air and Draft Pressure Alarms and Control
8) Dedicated Logic Solver
 Packaged Boiler Control System – Burner Control
1) Mandatory Purging
• Prevent possibility of accumulations of combustible gas following an accident or
improper ignition sequence
• A timed purge must be proven. The code indicates there must be a means to ensure the
correct volume of air has been purged prior to light-off.
2) Permissive Interlocks
• High/Low Fuel
• Pilot Gas Pressure
• High/low Stack temperature
• Loss of flame
• High/low firebox pressure
• Loss of combustion air
3) Double Block and Bleed Systems
• Safety shut-off valves installed in a double block and bleed configuration are
standard on main and pilot headers as well on each individual burner if more
than one burner exists.
• Bleeds are closed on light-off and open on shutdown.
Packaged Boiler Control System – Burner Control
 Packaged Boiler Control System – Burner Control
4) Pilot and Ignition Systems
• There are still many manual ignition systems present today
• There are electronic systems available consisting of an ignition rod and a
high voltage ignition transformer.
• When the interlocks are cleared and permissives in place, the pilot
burner can be lit which in turns lights the main burner.
• A continuous pilot is recommended for safe standby mode of operation
and negates the need to re-purge the heater if the main burner
shutdown.
5) Dedicated Flame Monitoring Systems
• Each burner is required to have its own flame monitoring device as well
as the pilot and the main flame.
• Typically a flame rod is used to monitor the pilot flame and a UV or IR
scanner to detect the main flame. The temperature on the main flame
would be too hot for a flame rod.
 Packaged Boiler Control System – Burner Control
6) High/Low Pressure, Temperature and Flow Control
• While switches have been used commonly in the past, there is a
recommendation to use transmitters since switches may fail in an unsafe
position. Transmitters can relay dynamic information and may have built-
in diagnostics.
• High/Low fuel gas and pilot gas pressure used to ensure burners are
operated within the design parameters.
• Temperature alarms are used to indicate improper operation and warn
of an uncontrolled fire.
• If forced draft or blowers are required to provide combustion air to the
blowers, a low combustion air flow alarm must be used.
7) Combustion Air and Draft Pressure Alarms and Control
• Combustion draft pressure is a critical measurement in the operation of a heater.
Draft pressure will adjust the dampers accordingly to ensure that the proper
pressure is achieved. If the pressure cannot be achieved the burners firing rate
must be reduced.
 Packaged Boiler Control System – Burner Control
8) Dedicated Logic Solver
• Most traditional burner management systems were hardwired with
relays and switches which can be easily bypassed. There is a potential of
bypassing important permissives and interlocks resulting in an unsafe
system.
• The use of a Programmable Logic Controller (PLC) or Distributed Control
System (DCS) can be used a primary safeguard however they must be
designed so that a hardware, software or power failure will still ensure
that the systems reverts to a safe condition.
• A separate manual emergency switch must still be available that is
independent of the PLC or DCS and will ensure a safe shutdown.
• Since BMS systems are a safety system, a SIL (Safety Integrity Level) rated
PLC or DCS system should be used. SIL levels are an indication of the
probability that the piece of equipment will function as it was intended.
There are four SIL levels, 1 to 4, with 4 being the safest system.
 Packaged Boiler Control System
Burner Start-Up Sequence

© Onquest
 Packaged Boiler Control System
Typical Boiler - BMS Devices

© Rockwell automation
 Packaged Boiler Control System
Typical Boiler – Combustion & Level

© Rockwell automation
 Packaged Boiler Control System
Typical Boiler

© Yokogawa
 Packaged Boiler Control System
Overall Boiler Start-Up Sequence
Note: This is a typical boiler sequence. The start-up sequence may vary due to the
nature of the particular boiler as well as the reason for the last boiler shutdown.
This sequence also takes into account that the boiler and all related
instrumentation devices have been commissioned and deemed operational.
1) Ignition: Pre-purge, reduction of air flow for stable ignition, pilot burner
ignition, main burner ignition (as described in the BMS).
2) Bringing the boiler up to normal conditions
• A boiler depending on its size and length of shutdown time must be brought up to
normal conditions at a different rate.
• It is important not to thermally shock the metal which will cause thermal expansion.
Keep an eye out for hot spots on the metal.
• Check draft pressures, fans, and feedwater pumps for normal operation.
3) Steam header warm-up
• The steam headers also need to warm up to avoid thermal stress
• Also it is important to ensure condensate is not formed. This can be achieved
by closing the header stop valve and opening up the header drains as soon as
ignition has been obtained. The stop valve can be reopened when the boiler
is up to normal operating pressure.
 Packaged Boiler Control System
Overall Boiler Shutdown Sequence
1) The boiler should have a good blowdown to remove as much sediment as
possible before shutting down the boiler. This can conclude when the
drains run clear.
2) Slowly reduce the firing rate. This is typically completed by placing the
boiler steam pressure control in manual mode. Do not reduce the fire rate
below that necessary to maintain a stable flame. (Also ensure that other
boilers are capable of taking up the load if you do not want to lose the
steam header completely.)
3) When the boiler is at its minimum fire rate, shut off the fuel supply.
4) Allow the fan to complete a post-purge cycle.
5) Close the boiler header stop valve.
6) Open a steam drum vent valve when the boiler pressure drops slightly
below atmospheric pressure to ensure that a vacuum is not formed.
Marine Boiler Cutaway
 Marine Boilers - Use of Steam
1) For propulsion uses to drive steam ships (Steam engine largely replaced by two
or four stroke diesel engines)
2) Electric power generation on steam and few motor ships
3) Used to drive cargo pumps in tanker ships to transfer oil
4) Winch and windlass driven by steam in some ships like tankers
5) For operation of cargo oil pump on most oil tanks
6) Taking or making vacuum inside the condensers on board of steam ships
7) Stripper pumps are driven by steam (on steam ships)
8) Cargo heating on steam ships and motor tankers
9) Warming up engines in cold areas prior to starting
10) Operation of ship whistle on all steam ships and few old tankers
11) Heating of fuel oil (ie/ heavy oil) and lubrication oil)
12) Soot blowing
13) Derrick on some ships is steam driven
14) Heating of accommodations in cold seasons
15) Sea Chest blow through