An Overview on Steam Boiler Failure and Breakdown
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
- Published in Boiler
A Guide to Select Ideal Steam Boiler for Process Plants
Steam Boilers are the heart and soul of the process and manufacturing industries globally. Boiler manufacturers are working consistently with their research and development department for advancement in thermal engineering by introducing steam boilers with enhanced design, offering efficient and sustainable performance. With the emergence of reputed boiler manufacturers, process industries consider every factor before deciding on a steam boiler for their facility. Rakhoh Boilers, as a leading boiler manufacturer in India, ensures to deliver excellent steam boilers to their clients that are efficient and reliable in process operations. As a staunch supporter of advancement in thermal solutions, Rakhoh boilers have listed some important factors that process plant managers must consider before choosing a steam boiler.
Importance of Steam Boiler Selection:
Steam boiler selection plays a crucial role in increasing the overall efficiency of a processing plant. When choosing an industrial steam boiler, it is necessary to consider the specific requirements of the process operation. Compared to the fuel cost, the initial capital cost on the steam boiler is merely 15 % or less in the life span of the steam boiler.
The two most commonly used boiler types in process plants are firetube boilers and water tube boilers. Although firetube boilers are less expensive and operate easily, it includes a relatively small steam capacity. On the other hand, water tube boilers efficiently produce high-pressure steam and are usually preferred in applications requiring higher capacity.
However, other considerations should be accounted for while selecting the appropriate steam boiler and boiler manufacturer for your process plant requirements. These factors include:
- Boiler Design / Type:
Firetube boilers and water tube boilers are the two primary types of steam boilers used in process plants. Firetube boilers pass hot gas from a heat source through tubes placed in a water-filled shell that converts the water into steam. Firetube boilers require a low capital cost and are usually easily operated. However, they come with relatively small steam capacities.
On the other hand, water tube boilers pass water through the tubes heated by hot gases in the boiler shell. Although it consists of higher thermal efficiency as compared to firetube boilers, it is more expensive. Water tube boilers are generally used to produce high-pressure steam and are majorly found in applications requiring high capacities.
- Fuel/Heat Source:
The fuel type for generating heat is also an important factor to consider for selecting a steam boiler. Some of the primary fuel types used in steam boilers include:
Coal:
Coal-fired boilers are usually known for higher emissions, requiring expensive scrubbers and electrostatic precipitators for the removal of harmful gases and fly ash from flue gas.
Natural gas:
Gas-fired boilers are ideal for natural gas fuel that is cleaner than other energy sources, is highly combustible, and has a high energy-to-heat ratio. It also ensures relative safety for storage purposes and provides certain environmental benefits over other fuel sources.
Biomass:
Biomass-fired boilers are used primarily in the sugar, paper, and distillery industries as it uses the by-products of the operational processes as fuel and is significantly economical in process plants with biomass fuel available readily and cost-effectively.
- Proper Combustion:
Steam boilers offering combustion with coal, biomass, or petrochemical fuel uses different combustion technologies. For example, stoker uniformly spreads the coal through the burner on a moving grate. On the other hand, fluidized bed technology includes air bubbles through a bed of pulverized coal or biomass that provides oxygen for combustion. These technologies impact thermal efficiency. Therefore, steam boiler selection should consider proper combustion along with the capital and operating costs.
- Safety:
High pressures and temperatures can contribute to hazardous accidents in steam boilers. It is also advisable by boiler manufacturers to approach and operate low-pressure steam boilers with caution. While selecting a steam boiler, decide on the safest option that meets the requirements of the process plants. It is also vital to understand the maintenance required for the safe operation of the chosen steam boiler.
- Reliability:
Reliability is one of the most crucial factors as the process operations depend tremendously on a steam boiler. It is important to assess the water quality as it has a significant impact on the performance of the steam boiler. Water softeners, demineralizers, or reverse osmosis systems are the best methods to improve feed water quality.
- Cost:
It is natural for the process plants to consider the cost of the steam boiler as a priority of their purchase criteria. Although cost is important, while considering variables like run hours and fuel costs, it is challenging to know the precise cost of the steam boiler. Simply put, a cheap boiler is likely to cost more expenses down the road.
- Life Span Expenses:
Calculating and assessing the expenses of life span economics is an important consideration. Finding the minimal life cycle cost includes factors, such as initial cost, operating schedules, estimated steam boiler life, overall boiler efficiency, warranty, annual operating expenses for parts, and blowdown requirements.
- Performance of Steam Boilers:
Steam boiler applications may require additional performance with heat or pressure that is lost at a significant expense if the steam boiler fails. High-performance steam boilers provide consistent and dependable operation for these applications.
About Rakhoh Boilers:
Rakhoh Boilers has been a trusted boiler manufacturer since 1983, delivering a range of efficient and reliable steam boilers, waste heat recovery systems, thermic fluid heaters, and boiler accessories. We provide excellent boiler services to ensure optimal efficiency and productivity of the steam boilers to your clientele, spread over 26 countries worldwide.
For more information on our products and services, visit www.rakhoh.com
- Published in Boiler