Steam Boilers are undeniably one of the important components of various process industries. They play a significant role in the heating, drying, and manufacturing process by generating steam through combustion. Therefore, it is safe to say that boilers are indeed, the backbone of almost every processing industry. However, it must be ensured that the boiler and its parts are always free from any malfunction to ensure the safety of the operating plant and personnel by regular boiler inspection.
Negligence over steam boiler maintenance not only results in additional expenses for repair but can also prove dangerous to the safety of the operating staff. Boiler explosions have the potential of causing as much damage as a bomb blast. Experts have found that the explosion of boilers takes place due to overlooking the safety precautions. Therefore, it is pivotal to note that boiler safety precautions must be considered a serious matter to avoid fatal accidents by training the staff to act quickly and accordingly in emergencies.
It is prudential to ensure the boiler safety precautions of the process plant by following the mentioned safety tips and ways to deal with emergencies.
Transportation in External Location in case of Compact Boilers:
Although boilers are generally installed in a closed room to ensure smooth and efficient operations, they may be a cause of difficulty during emergencies that may turn more problematic with the presence of a boiler. If the boiler is compact in design, arrangements must be made to shift it outside in emergency situations.
Safety Gears:
The operating staff must wear safety gear such as gloves, goggles, respirators, hard hats, and appropriate dress and shoes of standard quality during process operation. It helps in safeguarding the staff from any injuries or accidents.
Proper Disposing:
It is crucial to take care of the disposing of wastes in proper and allotted bins, especially in the case of oily or flammable wastes to keep away from any fire accidents.
Operating Pressure and Feedwater Quality:
The design pressure and feedwater quality might not seem to be an important factors, but they have a tremendous role in the smooth functioning of the boiler. Boilers above the design pressure and utilizing feed water of poor quality may cause scaling and corrosion that may lead to harmful consequences.
Regular checking of Safety Valves and Accessories:
Proper attention must be given to safety valves, air vent valves, blowdown valves, steam pressure gauges, ID Fans, FD Fans, and other accessories to ensure that the process operation takes place efficiently.
Regular Boiler Inspection and Maintenance:
Apart from making sure to follow every boiler safety precaution, it is advisable to conduct regular boiler inspections and servicing under the expertise and guidance of boiler manufacturers for detecting any forthcoming dangers, measures to prevent it, and thereby increasing the efficiency and life cycle of the boiler.
Staff Training:
As the saying goes, prevention is better than cure. And there is no better prevention than training the operating staff about the acceptable and safe measures to perform during operations and any emergencies.
Arrangements for Emergency Shutdown:
There are instances when process plants are required to shut down their boilers immediately and call for service. Therefore, the staff must be trained under expert guidance regarding the proper way of shutting down the boilers to avoid further damage and loss.
Evacuation Plan:
Regardless of assuring every possible boiler safety precaution, one cannot be certain of emergencies or breakdowns. Therefore, process industries need to make sure that appropriate evacuation plans such as fire exit, fire extinguisher, etc. are available and known to the staff.
Rakhoh’s Excellent Services for Industrial Boilers:
Rakhoh, as a leading name in steam boiler manufacturer, understands the paramount importance of regular servicing and boiler inspection for uncomplicated process operations. With our 38 years of expertise and experience in thermal engineering and solutions, we provide boiler-related services such as:
- Steam System Solution
- Energy Audit
- Boiler Automation
- Steam Trap Assessment
- Customized Solution
- Furnace Maintenance and Repair
- Annual Maintenance Contract
- Customer Training Program and much more
Know from the Experts:
1. How frequently should a boiler be inspected?
It is advisable to inspect the boilers annually under the supervision of experts to ensure their safe functionality. The experts, in particular, check safety valves and the interior of the boiler that includes both the fireside and waterside.
2. What factors or components must be a priority while inspecting the boiler?
The boiler should be inspected thoroughly, to make sure that it is safe for operations. However, some of the main factors that may severely affect the boiler efficiency are
- Overheating
- Scaling
- Corrosion
- Damaged Vessel parts
3. How can we identify faults that may lead to damages in the boiler?
- Some details need to considered seriously even though they may not seem harmful such as
- Unusual Noises
- Damaged Insulation
- Improper Water Treatment
- Stains that may indicate steam leakage or corrosion
4. What to check in the boiler before the expert inspection?
Before the expert or inspector arrives, check the following factors to determine the extent of inspection and repairing required,
- Operational check to assess the boiler control
- Safety Valves
- Temperature and Pressure control
- Pressure gauges, etc.