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Description
Boiler Operator's Handbook, 3rd editioneBook Description With the increased interest in climate impacts, sustainability, energy costs and energy efficiency goal, more responsibility is being placed on boiler operators to help improve system performance and reduce emissions. This third edition of the Boiler Operators Handbook is intended to help such operators in the quest for improved operability and performance of their boilers and their industrial plants. The theme of this book is to
eBook Description
With the increased interest in climate impacts, sustainability, energy costs and energy efficiency goal, more responsibility is being placed on boiler operators to help improve system performance and reduce emissions. This third edition of the Boiler Operator’s Handbook is intended to help such operators in the quest for improved operability and performance of their boilers and their industrial plants.
The theme of this book is to "operate wisely". The goal is to instill not only "know how" but "know why". The main details have been provided by the original author, Mr. Ken Heselton. This updated version has been somewhat expanded to include a wider range of examples and some of the more recent environmental requirements.
To illustrate these points, topics include multi boiler operations, understanding the plant load, maintenance issues, and controls. Every plant is different. However, it is hoped that with the information provided in this book, the wise operator will be able to address the various unique issues posed by the specific plant and provide timely solutions to meet the present-day requirements.
Table of Contents
- Chapter 1 — Operating Wisely
- Why Wisely?
- Prioritizing
- Safety
- Measurements
- Trends And Charting
- Flow
- Pressure Drop And Flow
- What Comes Naturally
- Water, Steam, and Energy
- The Steam and Water Cycle
- Combustion
- The Central Boiler Plant
- Electricity
- Documentation
- Standard Operating Procedures
- Disaster Plans
- Logs
- Chapter 2 — Boiler Plant Operations
- Operating Modes
- Valve Manipulation
- New Startup
- Dead Plant Startup
- Normal Boiler Startup
- Emergency Boiler Startup
- Normal Operation
- Safety Testing
- Idle Systems
- Superheating
- Switching Fuels
- Standby Operation
- Rotating Boilers
- Bottom Blow Off
- Continuous (Surface) Blowdown
- Annual Inspection
- Operating During Maintenance and Repair
- Code Repairs
- Pressure Testing
- Lay Up
- Tune Ups
- Auxiliary Turbine Operation
- Power Turbine Operation
- Chapter 3 — What the Wise Operator Knows
- Know The Load
- Know The Plant
- Matching Equipment to the Load
- Efficiency
- Performance Monitoring
- Modernizing and Upgrading
- Chapter 4 — Special Systems
- Special Systems
- Vacuum Systems
- Hydronic Heating
- Boiler Water Circulating Pumps
- HTHW Boiler Plants
- Organic Fluid Heaters and Vaporizers
- Service Water Heating
- Waste Heat Service
- Once-Through Boilers
- Engines and Emergency Generators
- Gas Turbines
- HRSGS and Combined Cycle Plants
- Chapter 5 — Refrigeration And Air Conditioning
- Refrigerants
- The Refrigeration Cycle
- Refrigerant Superheat and Sub-Cooling
- Evaporators
- Freezing and Ice Storage
- Compressors
- Condensers
- Throttling Devices
- Miscellaneous Components of a Refrigeration System
- Cooling Towers
- Air Conditioning
- Chapter 6 — Maintenance
- Maintenance
- Cleaning
- Instructions and Specifications
- Lock Out, Tag Out
- Lubrication
- Insulation
- Refractory
- Packing
- Controls and Instrumentation
- Lighting and Electrical Equipment
- Voltage and Current Imbalance
- Eddy Current Testing
- Miscellaneous
- Replacements
- Maintaining Efficiency
- Records
- Chapter 7 — Consumables
- Fuels
- Fuel Gases
- Fuel Oil
- Coal
- Other Solid Fuels
- Water
- Treatment Chemicals
- Miscellaneous
- Chapter 8 — Water Treatment
- Water Treatment
- Water Testing
- Pretreatment
- Boiler Feed Tanks and Deaerators
- Blowdown
- Chemical Treatment
- Preventing Corrosion
- Preventing Scale Formation
- Chapter 9 — Strength of Materials
- Strength of Materials
- Stress
- Cylinders Under Internal Pressure
- Cylinders Under External Pressure
- Piping Flexibility
- Chapter 10 — Plants And Equipment
- Types of Boiler Plants
- Boilers
- Heat Transfer In Boilers
- Circulation
- Boiler Construction
- Fire Tube Boilers
- Water Tube Boilers
- Trim
- Heat Traps
- Burners
- Pumps
- NPSH
- Fans and Blowers
- Cogeneration
- Gas Turbines, Engines, and HRSGs
- Chapter 11 — Controls
- Controls
- Self-Contained Controls
- Control Linearity
- Steam Pressure Maintenance
- Fluid Temperature Maintenance
- Fluid Level Maintenance
- Burner Management
- Firing Rate Control—General
- Firing Rate Control—Low Fire Start
- Firing Rate Control—High/Low
- Firing Rate Control—Burner Cut Out
- Firing Rate Control—Jackshaft
- Establishing Linearity
- Startup Control
- Firing Rate Control— Parallel Positioning
- Firing Rate Control—Add Air Metering
- Firing Rate Control— Inferential Metering
- Firing Rate Control— Steam Flow/Air Flow
- Firing Rate Control—Full Metering
- Firing Rate Control—Dual Fuel Firing
- Firing Rate Control—Choice Fuel Firing
- Firing Rate Control—Oxygen Trim
- Draft Control
- Feed Water Pressure Controls
- Instrumentation
- Chapter 12 — Why They Fail
- Why They Fail
- Low Water
- Thermal Shock
- Corrosion and Wear
- Operator Error and Poor Maintenance
- Appendix A — Properties of Water and Steam
- Properties of Water and Steam
- Appendix B — Water Pressure Per Foot Head
- Appendix C — Nominal Capacities of Pipe
- Appendix D — Properties of Pipe
- Properties of Pipe
- Appendix E — Secondary Ratings
- Appendix F — Pressure Ratings for Various Pipe Materials
- Appendix G — Square Root Flow Curve
- Appendix H — Square Root Graph Paper
- Appendix I — Viscosity Conversions
- Appendix J — Thermal Expansion of Materials
- Appendix K — Value Conversions
- Appendix L — Excess Air/O2 Curve
- Appendix M — Properties of Dowtherm A
- Appendix N — Properties of Dowtherm J
- Appendix O — Chemical Tank Mixing Table
- Appendix P — Suggested Mnemonic Abbreviations
- Appendix Q — Specific Heats of Some Common Materials
- Appendix R — Design Temperatures and Degree Days
- Appendix S — Code Symbol Stamps
- Bibliography
- Abbreviation
- Index
- Biography
Note: This is a single license Digital eBook PDF File that is downloadable and is password protected.
Author Biography
Carl Bozzuto has been in the power industry for over 50 years. He started his career at Combustion Engineering, the leading boiler manufacturing company. He was on startup on the first commercial SO2 scrubber in the US in the late 60s. He has held various positions in CE and its successor companies (ABB, Alstom) including General Manager of Fluid Bed Boilers and Vice President of Technology. He has been on the Board of Directors of the Council of Industrial Boiler Owners (CIBO) and is currently an Honorary Member. Since his retirement, he has been a class instructor for Electric Utility Consultants, Inc., teaching courses in boilers, coal power plants, combined cycle plants, and HRSGs. He was editor-in-chief and an author of the award winning textbook Clean Combustion Technologies. He is currently a judge for the Carbon XPRIZE for the XPRIZE Foundation. In 2020, Mr. Bozzuto was honored with the Albert Nelson Marquis Lifetime Achievement Award.
Editor: Carl Bozzuto
e-ISBN: 9788770225908
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4.2 ★★★★★
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Product Reviews
★★★★★ 5
K and N is the best
Size: CA12290-Premium
In my opinion, you can’t buy a better air filter. Been buying them for all my cars since the 1990s.
WAS THIS REVIEW HELPFUL?YesReportShare
Reviewed in the United States on December 8, 2024
★★★★★ 2
Does not fit 2023 Honda Accord as it says in the title
Size: CA12290-Premium, Size: CA12290-Premium
Does not fit 2023 Honda Accord as it says in the title. Seems like good quality otherwise.
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Reviewed in the United States on October 3, 2024
★★★★★ 5
Fits Toyota 2010 FJ cruiser
Perfect fit for a Toyota 2010 FJ cruiser. Install might have been the easiest cabin filter I've done in any car that new. Remove glove box, pull out the cover and replace it. Fits great and takes odors out from it sitting for 6 months in the driveway. No notice to less airflow when on any level of fan speed.
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Reviewed in the United States on May 30, 2026
★★★★★ 5
Comparison with POTAUTO filter: Very similar but cheaper
I bought a POTAUTO MAP 1033C and EPAuto CP846 cabin air filter to compare them for use in my 09 Legacy (gen 4). They both seemed comparable and are cheaper than most other, similar filters, though the POTAUTO was and still is ~33% more expensive than the EPAuto.
Both seem built well-enough, considering they're only being used as relatively low-flow cabin filters. That said, the EPAuto is slightly better, mainly due to the white trim piece being unattached along one side on the bottom of the POTAUTO filter. Almost certainly nothing that will affect its performance or longevity, but it is interesting considering it's the more expensive of the two. However, it must be kept in mind that this is an incredibly small sample size.
In one of my very scientific tests (/s), I held them up side by side and looked through them toward the sun (obviously being careful) to judge thickness/density and uniformity. Neither had any thin spots that I noticed, and they were pretty similar overall. One of them blocked slightly more light than the other, indicating more filtration, but I unfortunately don't remember which one. I feel like it was the EPAuto, but I don't really want to speculate as I could very well be wrong. What I do remember is that the difference was so minor that all else being equal, it wouldn't justify the cost difference between the two. In other words, even if the POTAUTO were the slightly better one, it wouldn't be worth the extra few dollars for the minimal amount of extra filtration.
In another test, I compared the filters to each other and the old filter (which I'm pretty sure was OEM, but certainly not a charcoal filter, so it was significantly thinner) by blowing air from a compressor through them. I held the nozzle at roughly the same distance from each on one side of the filters, and I held my other hand at roughly the same distance from each on the other side. The old filter, unsurprisingly, let much more air flow through. Both charcoal filters were much more restrictive due to their extra thickness, leading me to feel much less air coming through. Both were roughly the same. Both filters also held up just fine to the strong blasts of air.
I bought a couple other filters that I was going to cut to fit to use one or both with these filters as a pre-filter and/or additional charcoal layer. After the airflow test, I decided against this, as these are a lot more restrictive than OEM already, and I didn't want to push it, since that could at best cause issues with getting good airflow into the car, and at worst could damage the blower. If not for the fact many, many people have been using these and similar filters for a long time without apparent issue caused by this, I would hesitate to even use these. I haven't noticed a decrease in the airflow, but it's doubtful I would since I rarely turn the fan up past the first couple settings (usually have it on the first) if I have it running at all, and I have the center vents pulled out (to access the inside of the dash) which causes the flow at the vents to be reduced slightly.
TL;DR - Both the POTAUTO and EPAuto charcoal filters appear to be a good choice, with the EPAuto having a slight edge on build quality (based on my limited sample size of one each) and a cheaper price. Filtration appears to be very similar between the two, certainly not enough of a difference to warrant the extra price for the POTAUTO over the EPAuto. Flow is significantly more restrictive than OEM filter but doesn't appear to be an issue. I give the EPAuto 5 stars and the POTAUTO 4 stars, only because the value of the POTAUTO is a good bit less (very similar or possibly even inferior quality for 33% more money). I can't speak to their longevity or performance, but I don't imagine either should prove to be an issue.
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As a side note relating specifically to the Legacy: replacing the cabin filter in this car is a PITA. It's not overly difficult per se, but a serious pain and certainly not something you're going to do when you have a spare few minutes. I'd rate it probably around a 3.5/10 in difficulty and a 7/10 for annoyance. While you can sort of access it by removing the manual compartment, you can't remove the tray through that. So you need to actually take the whole glove box out, which requires removing the side panel, unhooking the string/loop that keeps it from falling all the way down, and removing a few plastic screws, which can be a bit of a pain (and apparently Subaru loves them since they're all over the car). A stubby Philips driver will be helpful. Once you have the glove box out of the way, you have to unscrew several more of those plastic screws to remove the plastic cover between the glove box and the filter. This hole is where you gain access. Be careful when removing the old filter as loose dirt and debris may fall out and make a bit of a mess. You don't really want to get any in the fan below it if you can help it. Reverse the steps to reassemble it, and remember to reattach the string. Getting the glove box back in its track can be a bit of a challenge; in my experience from doing it multiple times I've found you sort of half force it and half don't. That is, it'll likely offer some resistance even if it's lined up, so if you try to baby it you'll probably be there a while, but also play with the alignment a bit to see if you can get it without marring up the tab and the slot on the right side too much. All in all, expect to spend anywhere from 15-45 minutes on this, and make sure you have a standard length as well as a shorter or stubby Philips screwdriver. I have to say, when it comes to air filters, this car is horrible. The air intake filter is a pain to change, too--much worse than most if not all other cars I've done.
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Keywords: Subaru Legacy, fourth gen, fourth generation, 4th gen, 4th generation, 03, 04, 05, 06, 07, 08, 09, 2003, 2004, 2005, 2006, 2007, 2008, 2009
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Reviewed in the United States on September 29, 2017
★★★★★ 5
Good price on the part and 5 min install saved me $35
Fit fine in my 4th gen 4Runner took 5mins to install
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Reviewed in the United States on April 19, 2026
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