Boiler Operating System

A ship's boiler system generates steam, a versatile energy source used for propulsion and
various onboard services. The system includes a boiler drum, burners, an economizer, and a
superheater, each playing a vital role in the steam generation process. The main boiler typically
produces high-pressure steam for propulsion, while auxiliary boilers provide lower-pressure
steam for heating, domestic use, and other onboard
needs.

Key Components of a boiler system and their

Functions:

 Boiler Drum: This is where water is converted into steam.

 Burners: They mix fuel and air to create heat, which is
then used to boil the water.
 Economizer: This preheats the feedwater using waste
heat from exhaust gases, improving the system's
efficiency.
 Superheater: It further heats the steam, raising its
temperature and pressure for optimal use.

Pressure parameters of a boiler system

Onboard ship, boiler systems utilize varying steam pressures for different purposes. Main
boilers, often providing propulsion steam, typically operate at pressures ranging from 20 to 60
bars. Auxiliary boilers, used for other onboard services, operate at lower pressures, typically
between 6 and 15 bars. These pressures can fluctuate based on the specific vessel type and
propulsion system.

 Main Boilers: These are the primary source of high-pressure steam, crucial for powering the ship's
main engines, and often operate at 20 to 60 bar.
 Auxiliary Boilers: These boilers provide steam for various shipboard services, like heating fuel and
accommodation, and generally operate at lower pressures, typically between 6 and 15 bar.
 Pressure Regulation: Boiler systems include pressure gauges and safety mechanisms to monitor
and control steam pressure, ensuring safe and efficient operation.
 Low-Pressure Systems: Some auxiliary systems might operate at even lower pressures, like 3-4
bar, for heating and other specific tasks.
Capacity of different types of Boiler Systems
Marine boiler systems, including main and auxiliary boilers, vary in capacity depending on their
type and intended use. Main boilers, often water-tube boilers, can range from 10,000 to
300,000 lbs/hr steam capacity. Auxiliary boilers, typically smaller, can produce steam in the
range of 400-4000 kg/h. The capacity of a boiler is also influenced by factors like pressure,
temperature, and the type of fuel used.

 Main Boilers:

Water-Tube Boilers: These are commonly used as main boilers due to their higher pressure
and temperature capabilities.
Capacity Range: They can be designed for steam capacities from 10,000 to 300,000 lbs/hr,
with pressures ranging from 250 to 1250 psig and maximum temperatures up to 850°F (for
gas-fired units).
Examples: Babcock & Wilcox D-type water-tube boilers are a common example.
Usage: They are primarily used to generate high-pressure steam for main propulsion and
other high-demand services.
 Auxiliary Boilers:

Capacity: Auxiliary boilers are smaller than main boilers and are used for various onboard
services like heating, hot water, and other hotel services.
Pressure:
Auxiliary boilers typically operate at lower pressures than main boilers, ranging from 6-15
bars.
Example: Sunflame's automatic control system for auxiliary boilers can handle capacities
from 400-4000 kg/h.
Usage: They provide steam for heating fuel oil, accommodation, and other shipboard
systems.

Fire-Tube Boilers:
- These boilers, where hot flue gases pass through tubes surrounded by water, can also
be found on ships, particularly for lower-pressure applications.
 Working of Exhaust Gas Economizer
When the main engines run it gives out exhaust gas which is used by the exhaust gas
turbocharger. Even after the usage of the exhaust gas there is a good amount of heat energy
remaining in it. The exhaust gas has a temperature around 200°C. Which is utilized by the
economizer. The water is taken from the water drum with help of a centrifugal pump, which is
passed the tubes present in the exhaust gas economizer. The exhaust gas containing around
200 °C is passed through outside of the tube where the water is heated. Later it is passed to a
steam drum and further used for different purposes.

Key Components of Exhaust Gas Economizer:

 Heat Exchanger: The core component where heat transfer occurs between the exhaust gas and
the feedwater.
 Water Drum and Steam Drum: These drums are used for water storage and steam separation,
respectively.
 Piping and Valves: These components are used to circulate the feedwater and steam through
the system.
 Ignition System of boiler system
The ignition system of a boiler on a ship typically uses a pilot burner to ignite the main burner,
which then heats the boiler. The pilot burner, often using diesel oil, is ignited by a spark
generated by electrodes connected to a high-voltage supply. Once the pilot flame is established
and confirmed by flame sensors, the main burner, using heavy fuel oil or diesel, ignites.

1. Pilot Burner Ignition:

 Spark Ignition:
Electrodes, connected to a high-voltage transformer, create a spark that ignites the fuel
(typically diesel oil) in the pilot burner.
 Flame Detection:
Flame sensors on the pilot burner monitor the flame and signal the main burner to activate
once the pilot flame is stable.
2. Main Burner Ignition:

 Fuel Supply: Once the pilot flame is confirmed, the main burner receives fuel, usually heavy fuel
oil or diesel.
 Ignition: The pilot flame ignites the fuel entering the main burner.
3. Automation and Safety:

 Automated Control:
Many modern marine boilers have automated combustion control systems to ensure safe and
efficient operation.
 Safety Features:
These systems include features like purging sequences, double fuel shut-off valves, and low-
pressure trips to prevent unsafe conditions.

Construction & Materials of boiler system

Marine boiler systems are primarily constructed from steel, with various types used for
different components to withstand high temperatures and pressures. The main components
include a steam drum, fire tubes or water tubes, a combustion chamber, superheaters, and
refractory linings. Materials are chosen based on their resistance to corrosion, high
temperature, and high pressure.
 Key Materials and Components:

 Boiler Casing: Typically made of mild steel plates.

 Steam Drum: Constructed from mild steel plates, often with a baffle plate to prevent water
droplets from entering the steam outlet.
 Fire/Water Tubes: Cold-drawn seamless low-carbon steel tubes are common for heat transfer.
 Superheater Tubes: Employ alloy steels containing chromium and molybdenum to withstand
high temperatures and pressures.
 Superheater Tube Support: Heat-resistant austenitic steel is used for supporting the
superheater tubes.
 Steam Piping: Chromium-molybdenum low-carbon alloy steel is used for steam piping in the
superheater range.
 Economizer Tubes: Cold-drawn seamless steel tubes are used for heating feedwater.
 Water Drum: Similar to the steam drum, constructed from mild steel plates.
 Refractory Materials: Oxide-based materials like alumina, silica, magnesia, and zirconia are
used for insulation and heat containment within the furnace.
 Burners: Mix fuel and air to generate heat for the boiler.
 Combustion Chamber: The space where fuel is burned to produce hot gases.
 Heat Exchanger: Tubes or other components that transfer heat from the hot gases to the
water.
 Stack: The exhaust chimney for flue gases.
 Air Fans: Supply air for combustion.
 Controls and Accessories: Valves, pumps, gauges, and other components for controlling the
boiler's operation.

Specific Material Considerations:

 Corrosion Resistance: Materials like stainless steel and alloy steels are used in areas exposed to
corrosive substances, such as seawater.
 High-Temperature Strength: Alloy steels containing chromium and molybdenum are crucial for
superheaters and other components exposed to high temperatures.
 Creep Resistance: Materials need to withstand deformation under sustained high temperature
and pressure.
 Weldability: Welded construction is common, so materials must be weldable according to
relevant standards.

 Refractory Properties: Refractory materials need to be durable, insulating, and resistant to

chemical attack and thermal shock.