Page 227 - Boiler_Operators_Handbook,_Second_Edition

212 Boiler Operator’s Handbook

the process and refuse to let anyone tune a boiler until oil that is pushed back out will allow continued firing of
I’ve watched them do it. That’s because I’ve discovered the burner when it isn’t supposed to be.
many an operator that just doesn’t get it and can’t tune With heavy fuel oil make sure the sensing lines are
a boiler without turning a screw the wrong way or too full of the separating fluid by pumping some through
much to create a dangerous condition. If I’m not confi- the sensing line during start-up after the annual inspec-
dent about someone I just taught in a class I’m sure not tion. Light fuel oil and other liquids that burn are best
going to count on somebody that’s only read this book. for this.
If you choose to tune the controls of a boiler with-
out hands on training I can’t stop you but I will say that
you’re taking your life in your hands. One of my service LIGHTING AND ELECTRICAL EQUIPMENT
technicians who just retired after thirty two years in the
business was given the nickname “Boomer” for obvious Yes, in many plants you’re also the one that has
reasons. He was present for two boiler explosions that I to change the light bulbs, so do it wisely. With modern
can remember and several heavy puffs plus had a plant lighting technology there’s more choices in lighting
burn down shortly after he left. All that despite his skill. and you should take advantage of them. Many of the
In every incident that I investigated, and several I heard modern lighting fixtures are energy efficient but will
of, he wasn’t the one that created the unsafe condition. A not pay for themselves in electrical savings because they
lot of them occurred due to operator action before or af- cost so much more. So what! A fluorescent bulb has an
ter his visit. Unless you have the training to add to your average life of about 10,000 hours, five times that of an
confidence, and the confidence of a qualified instructor, incandescent. All you have to think about is the value of
I would strongly recommend you let the experienced your labor to replace one of those bulbs five times and
tune your boiler. the owner should be willing to pay the higher price.
Pressure and draft gauges require maintenance to Compact fluorescents, those curly bulbs, are be-
insure their readings are accurate and reliable. All pres- coming so common that their prices are dropping; so
sure and draft gauges in the plant should be checked they will pay for themselves in energy savings in less
for calibration every five years. If the gauge is observed than a year, on top of your labor savings. Typically you
constantly swinging (the needle is moving constantly) can replace a 60 watt bulb with a 17 watt fluorescent.
or it is subjected to frequent bumps (like the discharge Use that ratio to get an idea of the right size. LEDs are
gauge on an on-off boiler feed pump) they should be another story, very expensive but they have a life of
checked more frequently. The sensing lines of the gaug- about 100,000 hours (over ten years of continuous oper-
es require more attention than the gauge itself. Lines to ation) so they’re really invaluable for those applications
gauges (provided the gauge is protected by a siphon) where the reliability of the light is important. They take
should be blown down at least once a year and that blow about one quarter of the power of an incandescent bulb
should be long and large enough to fully flush out the for comparable illumination and even less in applica-
piping. tions that are not involved with illumination so, with the
Draft gauges should be checked for zero every time extended life, are fantastic for applications like control
the boiler is shut down. There is little pressure available panel indicating lights.
to blow them; don’t use compressed air because it has When I was designing and installing burner man-
little effect and it’s too easy to damage the gauges. Draft agement panels I always made sure I had spare light
gauge lines are normally fitted with tees and crosses bulbs because one would always blow. I insisted on test-
that permit cleaning them with a wire brush attached to ing every new system on a simulator in the shop before
special fiberglass extension rods; if they’re dirty that’s it went to the field. That way I caught all the little sur-
the way to clean them. prises before fuel went in the furnace. Almost always,
Another important annual operation is to ensure after a couple of days of testing, one or more indicating
there’s an air cushion in pressure sensing lines that are lights would fail. Some of that problem was solved by
supposed to have them and no air in sensing lines that going to transformer type lights but the best solution is
shouldn’t have it. Air in a sensing line can act like an ac- those LED indicating lights.
cumulator, compressing when pressure is applied to the When it comes to a question of what’s happening
system to take on liquid then expand when the system is because a light burnt out the reliability of LED lights
shut down to push the liquid back out. That’s not a good overshadows all the arguments about the little bit extra
thing for something like an oil burner gauge because the they cost. I would rather buy new LED light assemblies