Manufacturers of Boilers focus on producing highly effective and durable boilers for the process industries. Steam Boilers play a significant role in almost every industrial sector. With the use of steam boilers, processing has become more efficient, reliable, and swift. Steam boilers are therefore unarguably one of the most important units in any processing plant. Boilers work by heating the water from burning of fuels which generate steam of the desired temperature.
Steam boilers are used in various manufacturing industries such as pharmaceuticals, chemicals, paper, textile, distilleries, etc. They are also used to generate power through turbines or engines. Therefore, the manufacturers of boilers ensure that boilers produced by them are efficient and reliable as per the requirement.
However, along with operating steam boilers, it is equally or perhaps more important to regulate and maintain their safety measures. Neglecting the precautions may result in boiler shut down, boiler explosion, and fatal accidents and injuries in the process plants and the staff. Unmaintained steam boilers can be as dangerous as an explosive bomb. Regardless of the sturdy and sophisticated quality assured by the manufacturers of boilers, it is necessary to regularly maintain and inspect them to avoid any accidents or fatalities.
Although steam boiler failures can occur due to many factors, some most commonly found negligence that brings threat to the functioning of the steam boiler are:
Low Water Level: In many of the steam boiler failures, the main cause found is that the water level was lower than what was predetermined by the manufacturers of boilers. To understand this better, let us consider a Solid fuel boiler or a Multi fuel boiler that produces steam by boiling the water by burning fuels. The furnace made of steel can withstand high temperatures because of the presence of water. At this stage, if the level of water is less than expected, the steel tubes continue to get hotter, and after a point, fail in their mechanical energy. It may result in a breakdown or some catastrophic failure or mishap.
Feed Water Quality: The quality of feedwater is an important factor to consider while injecting it into steam boilers. Poor quality of feed water may cause a breakdown in boilers. It must be noted that the use of feed water is unique in different types of boilers and manufacturing units. If the feed water contains excess sediments, it may cause interference in the process of filtration that, in turn, causes a layer of the solid sediments to form on the piping. It causes overheating in the internal tubes that ultimately leads to breakdown or explosion in the steam boilers. Such explosions cause excessive heat in the manufacturing plants, and the oxygen level is reduced tremendously, making it highly dangerous for the concerned personnel.
Fuel Combustion Explode: It is common knowledge that combustion in steam boilers takes place after fuels are burned. Therefore, it is essential to check the burner of the boiler. Manufacturers of boilers suggest that regular assessment and servicing of the boilers are necessary. Oversight in fuel-burning or faulty gas lines can lead to dangerous blasts of gas leakages.
Improper Blowdown: The process of reducing the number of unrequired solids in the boiler is possible through feedwater and blowdown. The blowdown process helps in maintaining the solid aggregation in the solid fuel boiler or multi-fuel boiler as per their requirement. This solid aggregation includes suspended solids, dissolved solids, alkaline, and silica. A high level of blowdown is required as the operation of the boiler advances. However, if the water level remains high due to improper blowdown, it may cause the formation of sediments, excess moisture because of foaming, corrosion, and poor quality of steam. At such an occurrence, the solids and silica are carried with the steam and accumulate in internal parts of the boiler like the turbine and superheater. This formation, along with the high temperature may cause instability or shut down of boilers.
Precautions to Follow for Boiler Safety:
Certain precautions can prevent incidents of explosive boilers. Regardless of the boilers being solid fuel boilers or multi-fuel boilers, manufacturers of boilers advise following some steps to maintain safety and stability in the processing industry.
1. Regular checking of the boilers and their accessories to examine any potential faults or danger
2. Inspect if there are any leakages of steam, water, or flue gases from any part of the boilers
3. Cleaning of the part that is moveable or unfixed
4. Ensure that the water is treated before feeding it to the boiler
5. Follow the safety manual provided by the manufacturer of the boiler
6. Train and Educate the operating staff about the safety precautions while using a boiler
Rakhoh boilers have successfully manufactured and installed various types of boilers to their clients over the years. We provide Solid fuel boilers, Multi fuel boilers, oil fired boilers, and so on assuring that our boilers are of top-notch quality and safety. We also provide best services with periodic boiler servicing, maintenance, repair, and upgrading in boilers. Rakhoh boilers have always placed efficiency and safety as its utmost priority.