A steam boiler is essential for the proper functioning of the manufacturing and process industries. Process plant managers must ensure that the steam boiler is free from any catalyst that may cause boiler breakdown or boiler failure. However, various factors can negatively impact the performance of the steam boiler. Neglecting regular inspections and maintenance can lead to severe consequences like boiler breakdown or boiler explosion, resulting in a loss in process plant and injuries to the operating personnel. Therefore, it is vital to adhere to strict safety guidelines for steam boiler operation and use safety gear and equipment while handling.
Here are some of the common signs that indicate steam boiler failure:
Odor: Steam boiler failure can lead to the emission of strange odor/smell from the steam boiler.
Noises: Steam boiler making loud, unusual noises is a sign of the failure of the boiler system.
Leaks: Steam boiler failure causes leakages of water or other fluids.
Thermostat: Consistent adjusting of the thermostat is a sign of steam boiler failure.
High Bills: A tremendous increase in the heating bills, as compared to previous months indicates a boiler failure issue.
Hazards of Using Faulty Steam Boilers:
Faulty boilers on the verge of failure or breakdown result in hazardous consequences that severely impact the operating personnel. Carbon monoxide, also known as the silent killer, can be fatal if overlooked. The odor of spent gas and fumes are signs of the danger of steam boiler failure. In such situations, it is advisable to contact the steam boiler manufacturer. It is also important to look for any visible soot or spillage marks and take immediate action on them.
Another hazard in using a faulty boiler is combustion turning into a yellow flame, rather than the usual blue one. It is caused due to an excessive amount of carbon monoxide in the steam boiler that spills the harmful, fatal gas in the boiler room. In such cases, it is prudent to contact the boiler manufacturer immediately for guidance, and it is suggested to turn off the steam boiler promptly until help arrives.
How to Maximize the Lifespan of a Steam Boiler?
Lifecycle cost is one of the important factors to consider while selecting a steam boiler for an industry. Although the efficiency of the boiler system is crucial, it is not the only factor that ensures the optimal lifespan of the steam boiler. Generally, an industrial boiler system functions effectively for 20 to 30 years. However, various factors impact the performance of the steam boiler.
- Selecting a Modular Steam Boiler:
Nowadays, boiler manufacturers provide efficient and sustainable steam boilers through advanced research in thermal engineering. Such a steam boiler system generates the precise amount of steam needed to meet the industrial demands. Additionally, process plants can rotate modular boiler systems with the lead boiler. During low demand, process facilities need to operate only one boiler, known as the lead boiler.
- Proper Boiler Water Treatment:
Improper and insufficient boiler water treatment causes hard scale build-up that damages the steam boiler system over time and significantly reduces the lifespan of the steam boiler. In severe cases, it can lead to critical failures or even hazardous threats to the safety of the process plant and operating personnel.
- Automated Monitoring and Control:
Advanced monitoring and control components optimize the system efficiency and maximize the steam boiler longevity. Rakhoh Boilers provides the best services in boiler automation that monitor the steam boiler in real-time, detecting the issues before major issues, and suggestions to prevent boiler issues.
- Regular Boiler Maintenance and Inspection:
The most effective way to maximize the lifespan of the steam boiler is to schedule regular maintenance and inspection of the steam boiler to prevent any mishaps that may occur due to negligence in maintenance and handling of the steam boiler.
Signs for Replacing Steam Boiler System:
Although steam boiler failure or breakdown requires immediate attention, it may cost a fortune to the processing facilities. However, after two to three decades of operation, steam boilers need to be replaced for enhanced performance and higher efficiency. Some of the factors that determine the replacement of steam boilers are:
Safety problems are usually detected in scheduled safety inspections as the inspectors assess the condition of the pressure vessel and the safety devices in a steam boiler. Additionally, boiler operation should be monitored closely and the following factors must be considered,
High stack temperatures
Irregular stopping/starting of steam boiler
Excess cycling
Poor combustion tuning
Water hardness
Poor boiler water treatment
Steam boiler inefficiencies along with fuel cost are major factors to consider boiler replacement. In some cases, the repair costs are higher, that replacement seems to be a better economic decision.
Lastly, plant steam requirements change over time. Therefore, an oversized boiler operating in its low range is usually less efficient than a unit sized for the load.
Conclusion:
Rakhoh Boilers has been a leading boiler manufacturer for 38+ years, providing efficient and reliable industrial steam boilers, waste heat recovery boilers, thermic fluid heaters, boiler accessories, and boiler services to over 20 process industries in 26 countries worldwide. Our services include annual boiler maintenance, steam trap assessment, energy audit, boiler automation, fuel conversion, and much more.
For more details, visit our website www.rakhoh.com