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What is the principle operation of a boiler?

Boiler operation
Boiler working procedure:


The boiler is supplied with water by a feed pump. Water enters the boiler through a feed check valve. When the water reaches normal water level which is approximately the middle of the water gauge glasses, the feed pump is stopped by the dual control.
The burner is bolted to the hinged front door. Air required for combustion is provided by a forced draught fan which is integral with the burner unit.
The furnace receives heat radiant from the flame and the hot gases from the flame give up heat to tubes in the second pass as they travel to the front chamber. Gases turn into front chamber and give up more heat to the tubes in the third pass as they travel to the rear chamber. The gases leave the boiler by the chimney at the top of the rear chamber.

As the steam pressure rises the pressure has been shown in pressure gauge. When the pressure is sufficiently high the main stop valve can be opened to allow steam to pass to the process or heating system.

Which electrical components contain Boiler control Panel?

Control Panel:

All electrical equipment's p rewired to a control panel which is normally mounted on the side of the boiler. One also can made by own modulating or sealing dampers and final electrical connections. Most of the boiler connection fit a 3 phase 4 wire to the isolator within the control panel, however the boiler may have been supplied suitable for other electrical configurations. One boiler control panel contain

Sequence Time: Sequence Time is used for regulation and flame supervision of the burner.
Starters: Starters is used for forced draught fan/oil pump motor and feed pump motor.
Fuses, Relays and Switches used for control Functions
Indicator light and Alarms used for normal and fault conditions.




What is main Function of Boiler Safety Valve?

Why Boiler Safety Valve is more important?







Boiler safety Valve:

Boiler safety valve is one of important parts of boiler mounting and fittings. The boiler safety valve ensures that the boiler can not reach to excessive steam pressure, should the boiler limit control fail. The type of safety valve fitted or prepare as British Standard as a high lift type.

The safety valve settings has been adjusted prior to the boiler leaving ones manufacturer factory. A plate on the safety valve specifies the operating conditions for which the valve was supplied. Once set the valve setting must not be tempered with. To prevent this the padlock keys should be kept in a safe place under the supervision of responsible qualified person.


Why people more prefer Cochran Boiler?

The Cochran is a package unit covering a range of evaporations. The Cochran boiler is a three pass wet back design. The first pass is the furnace and the second and third passes are two nests of small bore smoke tubes. All plain tubes are expanded except for boilers with working pressure of 13.79 bar= 200 lb/inch2 and over when the second pass tubes are expande3d and seal welded into the reversal chamber.
All the required number of stay tubes and stay bars are fitted in all boilers. All stay tubes are welded into the tube plates and reversal chamber. Stay bars are welded into the tube plates. The flue gas outlet is normally positioned vertically on the rear casing.
The Cochran boiler internal access is through an elliptical manhole with a removable door which is provided on top of the boiler. A muddoor is fitted to each tube plate. Access to the rear chamber is achieved by removing the side doors of the rear casing. Whilst access to the front chamber is provided by opening a hinged doo…

How one Inspection of Charge Air Cooler

Inspection for Reuse Charge-Air CoolerInspection procedure of Charge Air Cooler






One first inspects the charge air cooler for cracks, HOLS AND DAMAGE.

Then inspect the tubes, fins and weld for tears, breaks and other damage when there has been seen any damage causes of charge air cooler to fail the air leak check as like as my previous article and charge air cooler must be replaced.


Install the charge air cooler and charge air cooler piping on the vehicle and also recommendation to all must be follow manufacturing recommendation. 


Also one must always clean and inspect the charge air cooler piping and hoses prior to installation.

How one clean the Charge Air Cooler

How one clean the Charge Air Cooler
Cleaning procedure of Charge-Air Cooler






 If the engine experiences a turbocharger failure or any other occasion where oil or debris is put into the charge air cooler and the charge air cooler must be cleaned.

Firstly remove the air cooler piping and then charge air cooler from the generator which done as following manual or manufacturer recommendations.

One must follow this caution during this cleaning the air cooler of a generator
Do not use caustic cleaners to clean the charge air cooler. Damage to the charge air cooler will result.
Flush the charge air cooler internally with solvent in the opposite direction of normal airflow. Shake the charge air cooler and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris. Continue flushing until all debris or oil is removed where the H2O runs clear.
When flushing one must keep the tubes on vertical directions.

If the debris cannot be totally removed from the charge air cooler, the charge …

How one Remove and Install of Generator Alternator?

How one Remove and Install of Generator Alternator?
How one Remove alternator from Generator?
Removing procedure of Alternator






Before removing Alternator
One must again follow this caution Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing firstly one should remove negative battery cables and then attach the battery cables last.
Disconnect the ground cable from the battery terminal. Then remove the drive belt from the alternator pulley.
Remove and tag all wires. And then follow the following steps Remove the alternator link capscrew. Remove the alternator mounting capscrew. Then remove the alternator.



How one install the Generator Alternator? Installing procedure of Generator Alternator:
Firstly assemble the alternator, the alternator mounting components must be tightened in the following steps a.Alternator to alternator bracket capscrew b.Lower brace to alternator caps…

How one test Generator Alternator?

Testing procedure of Generator Alternator
Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing firstly one should remove negative battery cables and then attach the battery cables last.







Acid is extremely dangerous and can damage the machinery and can also cause serious burns. Always provide a tank of strong soda water as a neutralizing agent when servicing the batteries. Wear goggles and protective clothing to reduce the possibility of serious body injuries.

Firstly disconnect negative cables and then any cables that lead to other battery boxesin the circuit.
Now one must operate the engine at high idle and measure the alternator voltage output to the batteries with digital multimeter.

One must again follow this caution


Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteri…

Initial inspection procedure of Generator Alternator

Initial Checking procedure of Generator Alternator

Visual Inspection procedure of Generator Alternator


Firstly one check the drive belt and alternator pulley to be sure the alternator is rotating.








One must follow this caution for one’s own safety.

Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing firstly one should remove negative battery cables and then attach the battery cables last.








Check the battery and all wiring connections.



Inspect the wiring for defects. Check all connections for tightness and cleanliness, including the slip connectors at the alternator and engine compartment bulkhead and connections at the battery. 

How one test Air in Fuel?

A replacement of fuel supply lines, fuel filters, fuel injection pump, high pressure fuel lines and injectors will let air enter the fuel system. Air in the fuel system will make the engine hard to start, run rough, misfire, and produce low power and cause excessive smoke and fuel knock.

Replacing procedure of Air filter, Fuel filter of Generator:




Replacing the fuel supply lines, fuel filters, fuel injection pump, high presser fuel lines and injectors will let air enter into the fuel system. One must follow the system to bleed the air from the system.








Since the fuel transfer pump provides positive pressure through the fuel filter and supply line to the fuel injection pump, loose connections or defective seals show as a fuel leak and not as an air leak.

For faster air purge small amounts of air can be bled from the fuel injection pump by operating the hand primer located on the fuel transfer pump or by cranking the engine.








One sees a source that is often overlooked for air to enter the fue…