Steam Boilers are indispensable for the processing operations in industries and require proper handling and maintenance for safe and hassle-free functioning. Overheating in the boilers is a major concern that poses a threat to the safety of the process plant and operating personnel. Overheating takes place due to various reasons, ranging from limescale build-up and blockages to faults within the steam boiler itself. During overheating in the boilers, the unit discerns that heat is increasing to an unsafe level, thereby indicating a safety feature that causes it to shut down. Earlier, neglecting overheating in the boiler would have led to a boiler explosion, with extremely hazardous consequences. However, such occurrences have become rare, but overheating in the boiler should still be addressed immediately to avoid accidents.
How to Detect Overheating in Boilers?
In most cases, the major indication of overheating in the boiler is a shutdown. Usually, it occurs when the boiler has overheated and the pressure within the steam boiler has risen to a hazardous level. The steam boiler will stop working to stop pressure from increasing to the level that causes the unit to explode. When the steam boiler stops working and indicates overheating, it is necessary to stop the water supply that will resultantly stop water from flowing into the unit and reduce the risk of pressure building in the steam boiler eventually leading to the risk of boiler explosion. It is also prudent to seek guidance from an experienced engineer or boiler manufacturer to fix the issue under their expertise and skills.
Causes of Overheating in Boiler:
There are multiple reasons for overheating in boilers that are not immediately noticeable. Therefore, it is vital to examine every component of the steam boiler to detect the root cause of overheating. Some of the commonly found causes of overheating are:
- Limescale Build Up:
The limescale build-up is caused by the hard water that chokes the heat exchangers and leads to overheating in the boiler. It can also be detected through a whistling sound occurring in steam boilers. Excessive limescale on the heat exchanger hinders the flowing of water, eventually causing the risk of overheating in the boiler.
- Failed thermistor:
Boilers include a thermistor that is the piece of equipment to measure the temperature of the water in a steam boiler. When it gets faulty, the water temperature can increase to dangerous levels that may result in causing the entire steam boiler to overheat. In most cases, it is advisable to replace the thermistor or ask help from an engineer or boiler manufacturer in severe cases.
- System Blockage:
Although system blockage used to take place in old steam boilers, it can occur in any heating system. However, the blockages in the system can also result in overheating in the boiler. If the steam boiler makes a lot of noise, or some radiators are unable to heat up properly, it indicates the blockage in the steam boiler system.Clearing the blockages by flushing the system before the steam boiler overheats is the solution to prevent system blockage from causing more severe problems.
- Faulty Pump:
Issues within the steam boiler itself can cause overheating in boilers. One such issue is faulty pumps that circulate water around the system. Improper functioning of pumps results in hot water staying within the steam boiler. When such an occurrence continues for a long time, it leads to overheating in the boiler. However, damaged or faulty pumps are fixed by replacing them with new pumps to ensure proper operation of the steam boiler.
Prevention of Overheating in Boilers:
Steam boilers become over-pressurized due to the failure of the pressure relief valve and other controls. Although the steam boiler is connected with an open piping system with radiators, the air vents in radiators close at normal operating temperatures. As a result, excessive pressure builds up with the failure of the gas valve or safety controls. Overheating in the boiler is a serious issue that should not be neglected to ensure the safety and proper functioning of the process plant. The best way to prevent overheating in the boiler is to perform regular and proper steam boiler maintenance to assess any needed repairs to be done to steam boilers before any issue causes hazardous consequences like shut down or overheat. Outdated steam boilers should be replaced for all the advanced safety features to prevent the dangers of overheating in the boilers.
Conclusion:
Rakhoh Boilers are a leading name for steam boiler manufacturers since its inception in 1983. To date, we have manufactured and successfully installed more than 3000 efficient steam boilers in over 26 countries globally. We also provide a waste heat recovery system, thermic fluid heaters, boiler accessories, and the best boiler services to ensure the efficiency and performance of the steam boilers.
To learn more about our products and services, visit our website www.rakhoh.com
