Qualities Of Best Boiler Services Technician and Boiler Manufacturers
Steam boilers, as we are aware, are an integral part of any process and manufacturing industry. However, after a few years down the road, the boiler systems start deteriorating and require expert attention. In such cases, it is prudent to consult a trusted boiler services technician or boiler manufacturers to decide on the best course of action. However, if there is no previous knowledge of boilers, working with a boiler technician can be a challenge. It can be difficult to determine the level of expertise or thoroughness of the technician. Regardless of how much you are aware or not aware of the boiler and the service it requires, there are certain criteria of every great boiler technician and boiler manufacturer that need to be fulfilled.
As one of the leading boiler manufacturers in India, Rakhoh has listed some of the essential qualities to look out for in boiler services technicians and boiler manufacturers.
Essential Qualities of Boiler Service Technician:
With our teams of factory-trained, highly-skilled technicians, Rakhoh adopts the most advanced technology to maintain, service, update, repair, and replace a vast range of equipment
Fully prepared before starting with the boiler issue:
Preparation is a vital stage in boiler services and helps a proficient boiler technician to work quickly and efficiently so that time is not wasted.
Examine the boiler room to fully understand the issue:
It is important to have a clear picture of everything that could be probably wrong with the boiler, so an experienced technician will assess and take a look around the boiler room to ensure that nothing is being overlooked.
They are willing to share their knowledge after identifying the problem:
The best boiler service technicians are proficient in their field and happy to share their knowledge about the issue with the boiler system. Most importantly, they share their knowledge in an informative way to help the customer understand the cause and solution of the problem clearly.
They remain on-site to assure the services take place properly:
A professional boiler service technician is committed to ensuring that the job is well done, and that means staying on-site until it is assured that the work conducted was successful.
Clear communication:
Regardless of understanding or not understanding exactly how your boiler technician is resolving the issue, communication needs to be open and clear about the happenings with the boiler and how it is being solved.
They leave no stone unturned in resolving the problem quickly and professionally:
An expert boiler service technician starts immediately with their business. Once they have identified and explained the problem, they get to the work of fixing the boiler as quickly as possible without wasting time.
Regular follow-up to be updated about the boiler’s condition:
Professional boiler service technicians reach out to clients after a short period to ensure that the repairs are leading to seamless operations and that the clients are satisfied with the work. At Rakhoh, we consider it the foundation of a great working relationship with our extensive clientele.
Essential Qualities of Boiler Manufacturers:
Rakhoh, as one of the trusted boiler manufacturers, prides itself on its expert knowledge and unparalleled ability to deliver fast, efficient, and effective solutions.
Years in the Business:
Similar to any other service provider, tenure is an important sign to determine the suitability of the boiler manufacturers. In other words, a boiler company that has been a reputed name in the business for an extended period would have been trusted by others for one or several reasons. In most cases, these reasons involve providing highly-effective and reliable solutions, resulting in the creation of a solidly loyal customer base.
Team of Skilled, Trained, and Certified Technicians:
Boilers and boiler equipment are complex and technical devices. While there are various similarities between different boiler types, each manufacturer’s equipment consists of certain nuances and preferences. As a result, it is necessary to select a boiler manufacturer and service provider who is properly trained to administer solutions for the boiler and the equipment.
Contracts for Maintenance:
Even though the boiler system is crucial, it is important to schedule regular maintenance and inspections before it stops working or begins to malfunction. Therefore, it is important to choose a boiler manufacturer and service provider that offer service contracts. It can help to assure that the equipment is properly serviced and maintained according to the intervals suggested by boiler manufacturers.
Networking of the Boiler Maintenance and Service Provider:
A reliable boiler manufacturer and service provider is always a part of the network. Any leading provider works closely with several boilers and auxiliary equipment manufacturers to make sure that they are using the latest and most effective tools and techniques based on factory specifications.
Rakhoh for reliable boiler services:
Since its formation in 1983, Rakhoh Boilers strives to enhance and improve the safety of the boiler operations by manufacturing and installing steam boilers of the highest quality to ensure the safety of the process plants and prevent any fatal accidents or injuries to the staff working and operating the plant. As one of the reputed boiler manufacturers, we have successfully installed 3000+ boilers in over 27 countries worldwide.
Learn more about our products and services by visiting www.rakhoh.com
- Published in Boiler, Boiler Retrofitting
Problems and their Solutions in Thermic Fluid Heaters
Thermic fluid heaters are gaining popularity in large industries due to their improved temperature control and reliability. Although steam boilers are still a vital asset for the manufacturing and process industries, thermic fluid heaters are slowly but surely emerging as preferred equipment. It offers enhanced performance, high temperature at low pressure, low maintenance, low operational cost, and minimal downtime. However, similar to steam boiler problems, thermic fluid heaters too face their share of issues that should be promptly addressed. Regular checking and maintenance of the equipment is the key to several issues. Some of the commonly found issues in thermic fluid heaters are as follows,
Problems during operations:
In the operation of a thermic fluid heater, the system provides radiant and convective heat to the heater tubing placed in the firebox. It is transferred to the film layer of the fluid through the tube wall. The fluid is in a turbulent state that causes the film layer to mix with the fluid and transfer the heat quickly. The high flow by the circulating pumps leads to swift transport of the heat by the fluid that returns at a lesser temperature to carry more heat.
At normal operations, the refractory and structural metal temperature is equal to the flame itself. After shutting down thermic fluid heaters, the heat in these components requires more time to radiate and exit the stack entirely. If the heater consists of excess refractory parts, it would require more time in radiating the excessive stored heat.
The fluid circulating after the shutting down of the heater carries the heat and distributes it to the entire system.
Boiling Point of Fluids:
The heat transfer fluids possess various boiling points, with larger molecules boiling at high temperature and smaller molecules at low temperature. The natural convection currents continue to flow in the firebox even after the flame is turned off. It causes the internal temperature to remain sufficiently heated for the mid-sized and smaller molecules of the fluid to vaporize. With smaller molecules boiled, the remaining large molecules continue to exist. The higher percentage of molecules reflects the higher viscosity of the heat transfer fluid.
As the liquid becomes thicker, it is hindered in flowing quickly through the thermic fluid heater and requires more horsepower for obtaining the flow. The slow-flowing fluids continuing to remain in contact with the heating surface results in reducing the system performance and overheating and damaging the thermic fluid system.
When the flow is reduced, it leads to increasing the temperature of the fluid’s film layer. It causes fluid degradation, and gradually, fouling of the thermic fluid heater with deposits and sludge.
Improper Shutdown:
When the thermic fluid heater is shut down entirely, the heater does not fire and the pump stops circulating the fluid. It results in transferring the stored heat in refractory and structural metal parts to the firebox. The heat does not exit the stack immediately after turning off the blower that causes extreme heat in the heater tubing that consists of heat transfer fluid.
Power Failures:
In case of power failure, it must be ensured to tie in the blower and circulating pump of the thermic fluid heater while using emergency power. Emergency power hook-up is cost-effective as compared to the expense of thermic fluid heater replacement.
Maintenance of Thermic Fluid Heaters:
Like every other industrial equipment, a thermic fluid heater needs regular maintenance and servicing for hassle-free performance. Factors that must be taken into account for efficient operations are:
Inspecting Insulation:
Proper insulation is vital for effective operations in thermic fluid heaters. It is essential to check that the heater insulation is in place and acceptable conditions.
Assessment of Piping:
A thermic fluid heater consists of multiple piping in it. Therefore, it is necessary to check the piping for any leakages, weak spots, or other flaws requiring repair or replacement.
Annual Inspection:
It is imperative to inspect the thermic fluid system annually under the guidance of a boiler manufacturer or professional to ensure its proper functioning. It is advisable to inspect and tune the burners for efficient performance.
Smooth functioning and preventing any mishaps are the primary concerns of every plant manager. To attain such goals, it is necessary to check the thermic fluid system by regular maintenance and repairing. In severe damage or issues, seek a professional boiler manufacturer for assistance and advice if a thermic fluid heater might be a better alternative than reparation.
Since its inception in 1983, Rakhoh Boilers have emerged as a leading boiler manufacturer and thermal solution provider. We manufacture a range of efficient industrial steam boilers, waste heat recovery systems, thermic fluid heaters, and boiler accessories. With over 3000+ successful boiler installations globally and our remarkable services, we have carved our reputation as a trusted boiler supplier.
To learn more about our products and services, visit our website www.rakhoh.com
- Published in Boiler, Thermic Fluid Heater
Managing Low Water Levels in Steam Boilers
Although steam boilers are imperative in the process and manufacturing industries, it is also a proven fact that it has the potential of explosive bomb. As water is vital for steam generation, it is also an essential factor that may harm the boiler system. Low water conditions are one of the leading causes of boiler incidents. It is necessary to keep water levels under check to ensure safe boiler operations. Low-water level conditions in the steam boiler take place when the water in the boiler drum drops below the low water level mark. It causes the potential to damage the boiler severely.
What is the Low Water Level in Steam Boilers?
A low water level in a steam boiler occurs when the water level falls below the lowest water level mark or even below the top of the tubes, consequently leading the tubes to overheat. If the water reaches a lower level than the main firing tube, it may fail the steel itself. However, it can be prevented with proper steam boiler maintenance.
As the furnace temperatures generally exceed 1,800°F (980°C), the strength of the steel falls significantly at temperatures above 800°F (480°C). Therefore, low-water levels may cause the melting of the steel tubes. As water enters an exceedingly overheated boiler, the water flashes to steam. The impacted metal parts rupture due to the sudden increase in pressure, causing a steam explosion.
Effects of Low Water Level in Steam Boiler:
One of the most hazardous cases of low water takes place when the water is added to the steam boiler, but the system has already passed the point of no return as the boiler vessel is extremely overheated. It causes the water to quickly turn into steam, resulting in tremendous pressure and the explosion of the steam boiler system. It is one of the most dangerous results for any boiler system and must be prevented.
Commonly found damage caused by low water levels includes:
Controlling Water Drum Level:
Controlling the boiler drum level is challenging as the water level in a steam drum is, in fact, an unstable combination of water and steam bubbles that shrinks and swells with the changing pressure. The increasing steam demand reduces the pressure in the boiler, causing the water level to rise. Additionally, as the freshwater enters from the feed tank and cools the drum water, it leads to the collapse of the steam bubbles and a drop in the water level. The solution for the shrink and swell effect in the steam boiler is opting for a 3 level drum control.
Low water conditions result from both operator and equipment issues. Some of the common causes include:
Low Water Cutoff Device:
Steam boilers are installed with low water cutoffs to prevent any significant damage. The devices operate to identify the low water condition and shut down the boiler system. The burner remains off till the water returns for the burner to fire normally.
Some low water cutoff devices serve the dual function of starting and stopping feedwater flow and stopping the burner. Such a device is known as the Primary Low Water Cutoff Device. A Secondary Low Water Cutoff Device serves another purpose of initiating a safety shutdown and lockout.
Failures in Low Water Cutoff Device:
Low Water Cutoff Devices are usually very reliable and well-functioning. However, the following factors can result in a breakdown.
Deposits: Condensate water and new make-up water enters a steam boiler and deposits minerals and solids.
Outdated models: Most boiler manufacturers recommend periodic replacement of the mechanical components of the steam boiler system. If overlooked, outdated boilers can lead to leaks and parts failure.
Loss of Water: Steam leaks and faulty steam traps requiring a high amount of makeup water cause issues in steam boilers and Low Water Cutoff Devices from loss of water. In such situations, the entire system requires proper maintenance.
Jumpers: At times, jumper wires are used temporarily for diagnosing a problem or bypassing a circuit for testing. If ignored, the Low Water Cutoff Device fails to shut down the burner.
Maintenance: Proper boiler maintenance needs the purging of the Low Water Cutoff Device system. It requires attention as improper flushing can also cause damage.
Conclusion:
As one of the world’s leading combustion experts and boiler manufacturers, Rakhoh specializes in thermal solutions. We have more than 39 years of experience in designing and manufacturing steam boilers and boiler accessories. Rakhoh offers a range of high-quality steam boilers that are compatible with a variety of fuels and applications.
For more details on our products and services, visit www.rakhoh.com
- Published in Boiler, Steam Boiler
Leakage in Steam Boilers and Preventive Measures
Steam Boilers are pivotal in manufacturing and process industries for heating and processing purposes. Although steam boilers are essential in industries, the maintenance of the boiler system is an important and challenging task for plant managers. One of the major steam boiler maintenance issues is boiler leakage. Boiler leakage should never be overlooked as it may lead to hazardous consequences such as corrosion of boiler components. Boiler leakages are found primarily during the winter season. It is because of the steam boiler operating overtime. As the temperature falls below zero, the water in the pipes and inside the steam boiler freezes into ice. Additionally, the condensate pipe removing the remaining steam and condensation from the steam boiler can freeze shut, hindering the steam boiler from functioning properly.
Detecting Boiler Leakages:
Determining boiler leakage helps in understanding the root cause of the leakages. It may be caused due to steam boiler pressure being too high or due to the pressure relief valve. Boiler leakages can be detected by
Causes of Boiler Leakages:
Let us learn some of the common causes of boiler leakages that can lead to the best course of action before causing any severe damage to the steam boiler system,
Pump:
The pump is a vital component of the steam boiler that constantly runs and circulates water in the entire boiler system. Due to its continuous operation, the pump valve or seal can break easily as the rubber seals are hardened or destroyed by elements passing through the steam boiler system.
The repair depends on the extent of damage caused to the pump. One solution involves resealing the pump with a gasket kit, while another solution suggests entirely replacing the boiler pump.
Pipes:
The pipes circulate water throughout the steam boiler system. Therefore, the pipes leading in and out of the steam boilers are possibly the reason for the boiler leakages. It is mostly due to improper installation or the degradation of pipe connection caused by corrosion over time. Both the issue requires the replacement of the component and proper installation.
Pressure Relief Valves:
The pressure relief valve safeguards the steam boiler system from generating excess pressure. During extremely high pressure, the steam boiler releases steam and water. Such situations can result in significant damage, and therefore, it is important to detect and address faulty valves as soon as possible. Pressure relief valves are repaired by removing lime or debris or resealing the valve.
Corrosion:
The rusting and corrosion in the boiler vessel deteriorate the boiler system and lead to water leakage. It is likely that the corrosion detected signifies an outdated steam boiler that needs immediate replacement. On the other hand, it is also possible that the corrosion is caused due to poor water quality.
A feedwater treatment system removes the harmful impurities, contributing to the build-up of scale in the steam boiler as well as the piping and fittings. Scaling in the steam boiler internals, safety equipment, and auxiliary piping indicates poorly treated feedwater.
Thermal Fatigue:
Thermal fatigue is usually caused due to improperly regulating feedwater temperatures and quality, resulting in boiler leakages. It is essential to assess the feedwater and examine if the feedwater temperature is too low as it leads to thermal shock cracking the welds in an area where the hot boiler water is introduced to the low-temperature feedwater. One of the primary issues internally of the steam boiler is the reduction of heat transfer to the components.
As the boiler tubes and tube sheets are the mediums between the hot combustion gases and the boiler water, the scale build-up can significantly reduce the heat transfer rate. It is because the scale acts as an insulator instead of a conductor. The reduction of heat transfer rate leads to overheating of the boiler components, causing metal fatigue and failure. It is mainly found in cases of cracks, ruptures, or complete boiler failure. Overlooking these issues can eventually result in boiler failures.
Preventive Measures for Boiler Leakages:
Short-Term Preventive Measures:
In some of the causes of boiler leakages, a simple fix is enough to avoid the leakages. If the water is leaked due to issues in the pump and pipes, resealing or replacing the part is ideal prevention. It is an easy and immediate fix that helps the steam boiler operate as soon as possible.
Long-Term Preventive Measures:
In certain situations, it is essential to replace the entire steam boiler system if the boiler leakage is caused by rust or corrosion. It indicates that the boiler is outdated and may fail in operating despite any short-term repairs.
Regular Maintenance:
Regular maintenance is the best method to avoid issues like boiler leakages by determining the cause at the initial stage before it can cause any damage to the steam boiler.
Conclusion:
Since our inception in 1983, Rakhoh Boilers have emerged as a leading boiler manufacturer in India and Overseas with 3000+ successful boiler installations in over 26 countries. Our product range includes efficient and reliable industrial steam boilers, waste heat recovery systems, thermic fluid heaters, and boiler accessories. We also provide excellent boiler services like energy audit, steam trap assessment, boiler automation, annual boiler maintenance, etc., to ensure the efficiency and productivity of steam boilers.
For more details, visit www.rakhoh.com
- Published in Boiler, Steam Boiler
Know the History and Evolution of Steam Boilers
Think about the world without steam. Transportation and communication were difficult, commerce was outdated, and processing industries were unheard of. The invention of the steam engine was an integral part of the industry during the Industrial Revolution. The term steam boiler is used to refer to heat generation. However, it is also applied to any type of equipment that heats water and stores or uses the steam for a specific purpose. The majority of steam boilers are considered high-pressure boilers. Pressure builds as large quantities of steam accumulate inside a contained vessel. When enough steam is produced, the released energy can power the moving parts of a machine.
The history and journey of advanced steam boilers found today go a long way back. Let us understand the evolution of steam usage and boiler manufacturing in the world.
The invention of the First Boiler:
It is said that the first-ever boiler existed as early as the 1st century. However, such boilers were nothing more than toys. Boiler manufacturing officially began in the 17th century as steam power was given importance for potential applications in daily life. The first steam boiler with a safety valve was manufactured in 1679 by France’s Denis Papin.
By the 18th century, steam boilers were used and manufactured in England from wrought iron. However, as the primary advantages of temperature and high pressure came into light, more and more boiler manufacturers turned to steel. The advanced steam boilers were made of alloy steel to withstand extremely high temperatures and pressures.
The History of Steam Boiler Manufacturing:
Looking at the history of steam boiler manufacturers in the USA, the first-ever steam boiler manufacturers were Steven Wilcox and George Babcock, founders of the steam-generating boiler in the U.S. The duo was the first to patent the boiler design that included tubes inside a firebrick-walled structure to generate steam.
A few decades later, in 1891, the two started the Babcock & Wilcox Company in New York. The first boilers of the company utilized lump coal and were relatively small that were fired by hand. Due to these factors, the first patented boilers by Babcock & Wilcox Company operated at an exceptionally less rate of heat input.
Introduction of Bent Tube Boilers:
As advanced technology changed the scenario, 1916 witnessed a new landmark for boilers. It was at this stage when an engineer brought improvement with bent tubes. The bent-tube discovery led to more compact boilers with an ability to handle the cold water feeds that were staples throughout this period.
Evolution of Cast Iron Bar:
As the bent tube boilers gained more popularity, the next improvement was cast iron boilers. Although bent tube boilers and fire tube boilers were ideal for delivering high-pressure steam, they also failed to provide efficient low-pressure steam for heating purposes.
However, the cast iron boiler came to be sufficiently durable for providing low-pressure steam. Although it was difficult to repair and heavy, cast iron boilers were manufactured in various types of shapes, a noteworthy change in the directional history of boilers.
Boilers in Post-War Industrial World:
During World War I and II, the marine boilers were highly dependent on the fuel steam-powered merchant ships and steam-powered combat boats. Marine boilers held an important place during the war years.
The post-war industrial world brought the need for more production from boiler manufacturers. The tube boilers were developed on a high scale. Later, the copper tube boilers gained popularity but presented a unique set of issues that required regular replacements.
Introduction of Condensing Boiler:
After the initial oil crisis in 1973 and environmental concerns in the 80s, boiler manufacturers started planning for more cost-effective solutions to minimize energy consumption in steam boilers due to an increase in energy prices. The solutions included operating boilers at lower water temperature and adjusting the water temperature in the boiler to the temperature outside. At present, condensing boilers offer an extensive range of benefits, such as:
Evolution of New Steam Boiler Design:
By the late 1970s and early 1980s, the growing disposal costs for landfills and increased demand for electric power led to the development of biomass-fired boilers. Steam boilers with fluidized bed technology were manufactured as an alternative method of burning solid fuels like coal. Depending on the boiler manufacturer, a fluidized bed boiler may include cyclones, combustion chambers, over-bed burners, collection hoppers, etc. The fluidized bed boiler involves a process through which solid fuels are suspended in an upward-flowing gas or airstream at the bottom. The burning fuel exists in a fluid-like state with a high heat transfer but reduced emissions.
Conclusion:
If you are looking for an efficient and reliable steam boiler for your process or manufacturing industry, Rakhoh is here to help. Since our inception in 1983, we have merged as the leading boiler manufacturers in the world. Our highly-skilled engineers will listen to your facility requirements and guide you to the best solution.
Learn more about our products and services at www.rakhoh.com
- Published in Boiler, Steam Boiler