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an -al-e! ,a iner#onne# 1e4een ,e pro$#er! an #on!$mer! o5 !eam. Seam #an 1e pro$#e an #on!$me a -ario$! pre!!$re le-el!. T,e!e i55eren pre!!$re le-el! are
!$rpl$!e! o5 !eam a ,i/,er pre!!$re le-el! #an 1e $ili@e a lo4er pre!!$re le-el!.Al,o$/, no !anari@e #ommonl $!e !eam pre!!$re le-el! in Sa$i Aram#o plan!
ran/e 5rom % o %2+ p!i/. Mo! plan! ,a-e a ,i/,>pre!!$re 7H:9 le-el o5 % o %2+
p!i/ pl$! one or m$#, lo4er pre!!$re le-el!. &or e?ample !eam pre!!$re le-el! a
A10ai0 are %2+ an % p!i/ an a Ra! Tan$ra ,e !eam pre!!$re le-el! are % 22+"+ an % p!i/. T,e!e %> o 22+>p!i/ le-el! are re5erre o a! mei$m>pre!!$re 7M:9
le-el!. U!$all ,ere i! al!o a lo4>pre!!$re 7L:9 le-el a "+ p!i/.
T,e !eam !!em 1e/in! 4i, ,e !$ppl o5 reae 4aer o a eaeraor 4,ere i!!ol-e
/a!e! !$#, a! o?/en an #ar1on io?ie are remo-e prior o inro$#ion o5 ,e 4aerino ,e 1oiler. T,e!e /a!e! are $ne!ira1le 1e#a$!e o5 ,eir #orro!i-e aa#6 on meal
!$r5a#e!. T,e 4aer i! eaerae 1 ,eain/ i o i! !a$raion empera$re an ,en!#r$11in/ i 4i, !eam o #arr a4a ,e i!!ol-e /a!e!. T,e eaeraor operain/
are $!e o eli-er B&8 5rom ,e eaeraor o ,e 1oiler !eam r$m. T4o or more p$mp!are pro-ie o en!$re a relia1le !$ppl o5 4aer o ,e 1oiler. 8,ere-er po!!i1le
#onen!e !eam 5rom ,e !eam $!er! i! #olle#e in a #onen!ae !!em an re$rne o
,e eaeraor 5or re##lin/.
#OI&ER C'ARACTERISTICS
Ty"es
T,e ,ree main pe! o5 1oiler! $!e 1 Sa$i Aram#o are 4aer>$1e 5ire$1e an
ele#ri#. 8aer>$1e 1oiler! are ill$!rae in &i/$re! 2 ,ro$/, +. T,e!e are ,e lar/e!an mo! #ommon 1oiler pe!. A 5ire$1e 1oiler i! ill$!rae in &i/$re % an an ele#ri#
1oiler i! ill$!rae in &i/$re '.
8aer>$1e 1oiler! ,a-e no real pre!!$re or !i@e limiaion!. T,e 1a!i# #on5i/$raion i! a
5ire1o? !$rro$ne 1 $1e! 5ille 4i, 4aer. Lo#ae a ,e op o5 ,e 4aer>$1e 1oiler
i! a r$m in 4,i#, !eam i! !eparae 5rom ,e 4aer. 8aer #ir#$lae! 5rom ,e !eam
T,e !maller>!i@e 4aer>$1e 1oiler! are $!$all !,op a!!em1le an eli-ere o ,e 5ielin a #omplee $ni. T,e!e $ni! are re5erre o a! pa#6a/e 1oiler!. T,e ma?im$m !i@e o5
pa#6a/e 1oiler! epen! lar/el on ran!poraion limi!. Lar/er $ni! #an 1e !,ippe in a
5e4 mo$le! 4,i#, are a!!em1le in ,e 5iel. Man Sa$i Aram#o 1oiler! are pa#6a/e$ni! 4i, ,e lar/e! ,a-in/ a #apa#i o5 a1o$ % l1,r o5 !eam a a e!i/n
Com1$!ion air i! !$pplie o ,e 1oiler 1 a 5or#e ra5 5an. T,i! air ener! ,e 1oiler
,ro$/, a 4in1o? 4,ere i i! i!ri1$e o ,e 1$rner!. T,e air mi?e! 4i, ,e 5$el in,e 1$rner! an #om1$!ion a6e! pla#e in ,e #om1$!ion @one o5 ,e 1oiler. T,ere are
man pe! an #on5i/$raion! o5 1$rner! epenin/ $pon ,e 5$el! 5ire an ,e !i@e
an e!i/n o5 ,e 1oiler.
Hea i! ran!5erre 5rom ,e 1$rnin/ 5$el an ,o /a!e! o ,e 4aer 4all $1e!
,e man$5a#$rer 1roa lai$e in !ele#in/ ,e mo! appropriae man$5a#$rin/
pro#e!!e!. T4o area! are #o-ere in ,i! !e#ion !pe#i5i#all 4elin/ an $1e
#onne#ion!.
Wel!ing
Boiler #omponen! are /enerall a!!em1le 1 4elin/. Mo! o5 ,i! 4elin/ i! one in,e man$5a#$rer! !,op. T,e 1oiler i! $!$all eli-ere o ,e 5iel in #omplee $ni! or in
!re!!e! in ,e 4el an ,e ajoinin/ 1a!e maerial! ,a e-elop $rin/ ,e 4elin/ pro#e!!. :o!>4el ,ea reamen i! al!o o5en re5erre o a! !re!! relie-in/. T,e
manaor re0$iremen! 5or po!>4el ,ea reamen are li!e in :ar. :8>3=.
Tempera$re! re0$ire 5or !re!! relie-in/ are in ,e ran/e o5 "">";& an m$! 1e,el $p o !e-eral ,o$r! epenin/ on ,e ,i#6ne!! o5 ,e 4el an ,e pe o5 maerial!$!e. An enire #omponen !$#, a! a r$m or ,eaer #an 1e !re!! relie-e a! a #omplee
$ni in ,e man$5a#$rer! !re!! relie-in/ 5$rna#e. Alernai-el ini-i$al 4el! or
/ro$p! o5 4el! #an 1e !re!! relie-e $!in/ pora1le ,eain/ elemen! ,a are pla#earo$n ,e 4el!.
T9;e Conne8tions
T,e major 5iel 4or6 on 1oiler pre!!$re par! #on!i!! o5 #onne#in/ $1e! an pipe! o
r$m! ,eaer! or o,er $1e! an pipe!. T,e!e #onne#ion! are ne#e!!ar in ere#in/
ne4 1oiler! an 5or repla#in/ $1e! or !e#ion! o5 $1e! a5er ,e 1oiler ,a! 1een in
!er-i#e. Mo! $1e! are #onne#e o ,e !eam an m$ r$m! 1 e?panin/ ,em ino,ole! in ,e r$m 4all. O,er #onne#ion! are mae 1 4elin/.
E<"n!e! T9;e Conne8tions
T$1e! are $!$all aa#,e o ,e r$m 1 e?panin/ 7or rollin/9 ,e en o5 ea#, $1e
ino a ,ole in ,e r$m 4all. A /roo-e i! $!$all #$ in ,e !ie o5 ,i! ,ole. A !pe#ial ool
7#alle an e?paner9 i! $!e o pre!!$re e?pan ,e $1e in ,i! ,ole lea-in/ ,e $1e 1earin/ i/,l a/ain! ,e r$m 4all. A pi#al e?pane $1e #onne#ion i! ill$!rae in
$1e e?en "; o 3; in. ,ro$/, ,e r$m 4all. Al!o ,e $1e en m$! 1e 5lare o an
o$!ie iameer o5 a lea! "< in. /reaer ,an ,e $1e ,ole. E?pane $1e #onne#ion!are /enerall !$ia1le 5or pre!!$re! $p o a1o$ "2 p!i 4,i#, #o-er! all Sa$i Aram#o
1oiler!. In !ome #a!e! 4,ere ,e $1e! are !$1je# o $n$!$al loain/ or empera$re
#oniion! lea6! ma e-elop in e?pane $1e #onne#ion!. In ,e!e #a!e! a !eal 4el#an 1e $!e o en!$re i/, #onne#ion!. T,e ma?im$m !i@e !eal 4el i! 3< in. an !re!!
relie-in/ i! no re0$ire. T$1e! !,all 1e re>e?pane a5er !eal 4elin/ a! re0$ire per
:ar. :8T "">".
In #a!e! 4,ere e?pane $1e #onne#ion! are no po!!i1le $1e! are 4ele o !$1! or
no@@le! alrea 4ele o ,e r$m or ,eaer. T,i! permi! ,e 4el! on ,e r$m o 1e
!re!! relie-e 1e5ore ,e $1e! are #onne#e.
$IGURE %, Ty"i8l e<"n!e! ;oiler t9;e
Tpi#al $1e #onne#ion! are !,o4n in &i/$re "+. T,e!e #onne#ion! are a6en 5rom &i/.
:o!>4el ,ea reamen i! /enerall no re0$ire 5or #ir#$m5erenial 4el! in $1e! 4i,
a ma?im$m !pe#i5ie #,romi$m #onen o5 3.J. T,i! !,o$l #o-er mo! #on-enional 1oiler an !$per,eaer $1e maerial!.
NONDESTRUCTIVE E=AMINATION
None!r$#i-e e?aminaion 7NDE9 i! $!e o i!#o-er 5la4! in maerial or 4el!. NDE
,$! a!!$re! !o$n #on!r$#ion o5 1oiler pre!!$re par!. NDE re0$iremen! are e!#ri1e
in Se#ion ( o5 ,e Coe. T,e 5ollo4in/ me,o! are $!e o e?amine ,e 1oiler
• Raio/rap,i# e?aminaion.
• Ulra!oni# e?aminaion.
• Ma/nei# pari#le e?aminaion.
• Li0$i peneran e?aminaion.• (i!$al e?aminaion.
E?#ep 5or #erain #a!e! ,e Coe re0$ire! ,a all lon/i$inal an #ir#$m5erenial 4el!
1e raio/rap,i#all e?amine. Raio/rap,i# in!pe#ion i! no re0$ire 5or man o5 ,e
5ollo4in/ pe! o5 4el!
• Small>!i@e #ir#$m5erenial 1$ 4el! in $1e! an pipe a! e!#ri1e a1o-e.
• Aa#,men 4el! !imilar o ,e pe! !,o4n in &i/$re "+ 7:ar. :8>"%."9 e?#ep
5or in!er>pe no@@le!. T,i! pe o5 4el i! e!!eniall a 1$ 4el an a #lear
raio/rap,i# pi#$re o5 ,e 4el #an 1e o1aine.
8,en i i! no po!!i1le o raio/rap, a 4el $e o ,e !,ape o5 ,e par or 4el ,e
Coe re0$ire! ,a ,e 4el 1e $lra!oni#all e?amine 7:ar. :8>"".29. Ma/nei# pari#lein!pe#ion an li0$i e peneran in!pe#ion! are al!o $!e o lo#ae !mall !$r5a#e
De5e#! in 4ele join! are repaire 1 re4elin/. Small e5e#! in ,e 1a!e maerial!are al!o repaire 1 4elin/. In aiion o ,e in!pe#ion pro#e!!e! li!e a1o-e e5e#!
al!o ma 1e 5o$n 1 lea6a/e e!!. De5e#! m$! 5ir! 1e remo-e $!$all 1 me#,ani#al
mean! !$#, a! /rinin/. T,e join #an ,en 1e re4ele an re>e?amine.
'YDROSTATIC TESTING
A5er ,e 1oiler ,a! 1een ere#e i i! !$1je#e o ,ro!ai# pre!!$re e!! o #on5irm
,a i ,a! 1een properl #on!r$#e. T,i! e! al!o en!$re! ,a ,ere are no mar/inal
• A #are5$l -i!$al e?aminaion 5or lea6! a ,e ma?im$m allo4a1le 4or6in/
pre!!$re. An lea6! ,a are 5o$n $rin/ ,i! e! m$! 1e repaire an ,e 1oiler
m$! 1e re>e!e. T,e ma?im$m meal empera$re! !,o$l no e?#ee "2&
$rin/ ,i! e?aminaion.
D$rin/ ,e!e e!! ,e 1oiler i! #ompleel 5ille 4i, 4aer. To ,e e?en po!!i1le all air
in ,e 1oiler i! i!pla#e. T,i! ma6e! i ea!ier o rea#, e! pre!!$re! an re$#e! ,e
poenial 5or#e! ,a 4o$l 1e relea!e in ,e e-en o5 a r$p$re. &or #omplee pa#6a/e
$ni! ,e ,ro!ai# e! i! #on$#e in ,e man$5a#$rer! !,op. A !e#on e! ma 1ere0$ire in ,e 5iel a5er ,e 1oiler i! in!alle. &or 1oiler! ,a are !,ippe in mo$le!
5or 5iel a!!em1l or ere#ion ea#, #omplee !e#ion i! ,ro!ai#all e!e in ,e!,op. A e! o5 ,e enire 1oiler i! #on$#e in ,e 5iel a5er ere#ion i! #omplee.
Con!ieraion m$! 1e /i-en o ,e empera$re o5 ,e 4aer $!e $rin/ ,e!e e!!.
8aer empera$re !,o$l no 1e le!! ,an am1ien empera$re an ne-er le!! ,an '&.T,i! minimi@e! ,e po!!i1ili o5 #aa!rop,i# 1rile 5ra#$re o5 ,ea- 4alle par! $rin/
,e e!. I al!o pre-en! an #on5$!ion 1e4een lea6! an #onen!aion on #ol o$er
T,e Coe al!o re0$ire! ,a no -al-e! 1e in!alle 1e4een ,e !a5e -al-e an ,e 1oileror 1e4een ,e !a5e -al-e an i! i!#,ar/e o amo!p,ere. Di!#,ar/e pipin/ !,o$l 1e
a! !,or an !rai/, a! po!!i1le o a-oi a 1a#6 pre!!$re on ,e -al-e. T,e pipin/ !,o$l
al!o 1e arran/e o a-oi $n$e !re!! on ,e -al-e. T,e i!#,ar/e !,o$l 1e lo#ae
8aer remo-e 5rom ,e 1oiler o #onrol ,e le-el o5 i!!ol-e imp$riie! in ,e 1oiler4aer.
#oiler Effi8ien8y
T,e raio o5 ,e ,ea a1!or1e 1 ,e 4aer an !eam 4i,in ,e 1oiler o ,e ,ea in ,e5$el 5ire. T,e 5$el 5ire ma 1e e?pre!!e in erm! o5 i! ,i/,er ,eain/ -al$e 7HH(9 or
lo4er ,eain/ -al$e 7LH(9.
Ctions
:o!ii-el #,ar/e ion! in ,e 4aer 5or e?ample #al#i$m ma/ne!i$m an !oi$m.
Boiler &ee4aer 7B&89Treae 4aer ,a ,a! 1een ,eae eaerae an o!e 4i, #,emi#al! o remo-e
re!i$al o?/en.
#9rner
A me#,ani#al e-i#e $!e o inro$#e air an 5$el ino ,e 1oiler a ,e proper #oniion!
A me#,ani#al e-i#e ,a $ili@e! !eam o #lean 1oiler $1e! 1 remo-in/ pari#le! o5
$n1$rne #ar1on or a!,.
Stem Dr9m
A #linri#al -e!!el near ,e op o5 ,e 1oiler ,a a#! a! a i!ri1$ion an #olle#ion
,eaer an a relea!e poin 5or !eam. T,e r$m al!o ,o$!e! !eparaion e0$ipmen o r,e !eam.
Stem T9r;ine
Seam $r1ine! are $!e o ri-e me#,ani#al e0$ipmen !$#, a! p$mp! or #ompre!!or!
an ele#ri#al /eneraor!. T$r1ine! ma 1e 5$ll #onen!in/ non#onen!in/ or e?ra#ion>
#onen!in/ pe!. In a 5$ll #onen!in/ $r1ine all ,e !eam enerin/ ,e $r1ine i!
#onen!e a5er i e?pan! ,ro$/, ,e $r1ine. A non#onen!in/ $r1ine $!$all e?,a$!!,e !eam o i!ri1$ion pipin/ a a lo4er pre!!$re ,an ,e inle pre!!$re. An e?ra#ion>
#onen!in/ $ni e?,a$!! par o5 ,e inle !eam a an inermeiae pre!!$re le-el an