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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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4.8 ★★★★★
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Product Reviews
★★★★★ 5
Hands down, the BEST handheld frother I've ever used!
Color: Black
Hands down, the BEST handheld frother I've ever used! I got the black one, but any color will have the same results.
Over the past 12 years or so, I've used so many different handheld frothers and they've ALL fallen short of expectations for quality, longevity, power, features, and usability.
I've used everything from cheap, $15 models to $50+ models and everything in-between. Some with fancy attachments for various types of mixing, frothing, beating, whipping, etc. Some with rechargeable batteries, some without. Some AC powered, some with fixed whisks, some with detachable/replaceable whisks, some with stands, etc. NONE have been spectacular. Most broke within 6 months and got tossed. ALL were major disappointments in the end, including the "revered" Zulay models of which I tried several.
I finally found this Maestri House branded, variable speed frother with detachable / replaceable whisks and got one to try. I was literally on Cloud Nine the first time I turned it on. Like, WOW! Not only was it FAST on the highest speed, but it was powerful enough to churn right through milk, eggs, cream, etc, without bogging down like many others.
This thing makes milk froth like a milkshake and Matcha Lattes like nothing else I've ever experienced. I used to have to sift my Matcha, then whisk it in hot water, then froth milk and then blend them together to make the perfect latte. and if the milk was cold (my preference), pre-whisking in hot water was a must to avoid lumps. However, with THIS frother? I literally pour my milk into a tall tumbler, drop in un-sifted Matcha powder, and spin up the Maestri House frother at first on a medium low speed to get it mixed, then jump straight to the highest speed to really whip that milk and match up. After about 30-45 seconds, I've got the thickest, richest, smoothest, most aerated latte around. And NO LUMPS at all!!! What a time and dish saver!
And cleaning? I just run it under hot running water to get the shaft cleaned and then spin it up in a dish with hot running water for a few moments, then spin it on high for a few seconds in the air to dry it off instantly.
Now, I'll be honest here, too. The specs say it can go months on a charge, using it for a couple minutes a couple times daily. Well, I guess it could do that and still spin. But I use it FULL SPEED, churning hard for at least a minute a couple times per day. After about 2 weeks, I can start to notice a speed reduction so I just plug it back in on the charger. All things considered, this is still better than all the other handheld frothers I've used over the years.
After using the heck out of this thing for the past 7 months, I've even decided to start selling these in our Japanese gift shop. The manufacturer is has been very responsive both in customer support (I called them about an issue I thought I was having, and they called me back with a couple hours even though I didn't leave voicemail when they didn't answer right away) and in reseller support. I have to give these guys an A+ for responsiveness and quick resolution when problems might arise.
HIGHLY recommended!!
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Reviewed in the United States on October 17, 2025
★★★★★ 5
Great Addition!
Color: Black
Why did you pick this product vs others?:
I just started a powdered drink routine recently and was having a difficult time mixing it with water. I would consistently end up with small nuggets of mix making it unenjoyable to drink. I knew I needed a mixer and was glad I found this device when I did. It works perfectly! I like the fact that it comes with its own stand and included two mixing heads. It is solid, well-designed, and you can feel the quality when you pick it up. The variable speed of the mixer is perfect for ensuring that everything is blended well. I haven’t used it to “froth” anything yet, at least not on purpose, but I accidentally found out that it can do that well. This is a great addition to our kitchen and is very easy to wash after use. So far…no issues. Highly recommend for those of you looking for the right tool to make sure those protein mixes aren’t full of unmixed nuggets.
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Reviewed in the United States on June 21, 2025
★★★★★ 4
Low foam
Color: Black
Love this frother. It is great quality and the turn speed is amazing. My only issue is this. It comes w 2 wands and they are both singles. The single is great for stirring things up. It does not make a lot of froth and for some things it’s perfect but sometimes I like a lot of froth and I wish it either came w a single and a double or you could purchase a double separately to intermix. I don’t want to buy a whole other unit just for the double. I wrote to them bc the double frother they sell doesn’t look as good as this one but sometimes a girl needs a lot of foam and sometimes th stirring is perfect.
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Reviewed in the United States on February 20, 2026
★★★★★ 5
Perfect for Lattes
Size: 20 Ounces
Good for steaming 8-10 oz of milk. The nifty tool is good for scooping out your puck.
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Reviewed in the United States on February 19, 2026
★★★★★ 5
Almost blew up my microwave
Size: 20 Ounces, Size: 20 Ounces
TL;DR "A hilarious microwave mistake turned into a great home cafe upgrade. This 20oz cup is straightforward to handle, looks incredibly professional, and holds a level of heat that will literally burn you if you aren't careful."
.
Bought this for homemade coffee brewing, just to spice things up. But as I go ahead to heat up my new shiny stainless steel milk frother cup in the microwave, whoopdy doo. Ya can’t put stainless in the microwave! Regardless, it’s still a straightforward frother cup to handle, making it a great dollar investment for upgrading my home cafe setup.
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1. Spotless Stainless Steel: Its sleek appearance made me feel professional in the hands of an amateur like moi. Great quality!
2. Temperature Retention: I accidentally burnt myself because it stayed so hot, but that is a major positive. Proving the insulation works perfectly and keeps the milk piping hot.
3. Size: The 20oz capacity is accurate, providing the perfect amount of space for frothing without any overflow.
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Reviewed in the United States on June 6, 2026