Steam Boilers are undeniably one of the most important assets for the manufacturing processing operation in several industries. However, it is also an acknowledged fact that if not handled properly, steam boilers have the potential of an explosive bomb. Several guidelines are followed during boiler operations and boiler manufacturers ensure that the steam boilers are equipped with safety devices. Yet, it is prudent to take every precaution rather than risking a boiler failure or explosion. Boiler spare parts are the solution to ensure extra safety and seamless operation of steam boilers. 

Here are 15 spare parts that should be present in every process plant.

• Auxiliary and Primary Low Water Cut-Off Switches:

Auxiliary and Primary Low Water Cut-Off Switches are vital to identify low water conditions in the boiler. It also ensures that a master fuel trip shut the burner off during such situations. On average, Low Water Cutoffs have a lifespan of ten years, provided that it is cleaned thoroughly on an annual basis. If maintenance is overlooked, low water devices require sooner replacement, and their reliability is reduced during operations. These level switches are essential to run the steam boiler safely.

• Pressure Control Device:

Pressure Control Device is a part of a PLC-based controller in large systems, whereas it is an independent pressure controller in smaller systems. The absence of such a pressure controller means that the operator assesses the boiler pressure gauge and manually adjusts the boiler firing rate to maintain system pressure without tripping the boiler or lifting the safety valves. It is a difficult task and not a reliable method of pressure control with precision. Therefore, a spare part like a pressure control device can enhance the safety of the steam boiler operation.

• Flame Detector:

A flame detector is an important boiler spare part that prevents the steam boilers from filling with raw fuel during the absence of flame. Several technologies are used in flame detection. In the case of industrial steam boilers, it is usually a flame scanner. Due to the sensitive nature of such devices, it is necessary to have boiler spare parts at hand for any emergency.

• High Pressure / High-Temperature Cutout Switch:

It is a simple pressure switch used for steam boilers. Combustion safety codes include this safety switch for every installation. Therefore, it is vital to install this relatively inexpensive part to avoid production loss.

• Safety Relief Valves:

Safety valve springs are damaged in a short period, causing venting of the valve even when pressure is not at a set point. The codes expect an annual inspection of safety relief valves. Therefore, it is advisable to have a boiler spare part in case of replacement during operation.

• Fuel Safety Shutoff Valves:

Fuel Safety Shutoff Valves ensure that the fuel does not leak into the steam boiler when it is off and prevent it from filling with fuel that can cause an explosion or runaway boiler fire. It is essential to have extra boiler spare parts for large valves to prevent requiring a full assembly. Although the valves can be repaired, in rare cases when they cannot, they can lead to steam boiler failure.

• Water Level Device: 

Feedwater control setups in steam boilers use different technologies and devices to control the water level. Operating a steam boiler without feedwater controls needs a full-time operator to adjust a manual valve. However, it does not make sense to have operators standing around with nothing to do. Therefore, it is essential to have boiler spare parts and a loop control device if something fails.

• High And Low Gas Pressure Switches:

High and Low Gas Pressure Switches are vital to ensure that the steam boiler is not receiving excessive or too little gas. The absence of these switches can result in steam boilers being too lean or rich and cause major damage or an explosion. Therefore, a spare must be kept installed by a qualified technician. 

• Gas Regulator:

Gas Regulators are probably the most overlooked boiler spare part in many process plants. But, it is important to have an extra on hand. It is also essential to inspect the regulator vent lines.

• Igniter Parts:

Lighting an oily rag on a stick is an outdated method of combustion in a steam boiler. Therefore, having a spare igniter is a good decision to ensure hassle-free combustion.

• Combustion Air Switch:

A combustion air switch stops a burner from opening the fuel valves in the absence of airflow. As the flow switch can prevent your steam boiler in its tracks, it is ideal to have a spare of it.

• Gaskets:

Gaskets are frequently replaced and made of different materials that depend on if they reside on the fireside or water side of the steam boiler. It is usually replaced every 12 months or during any inspections of the steam boiler. Since it is replaced so frequently, it is ideal to carry replacement or spare gaskets. It also shortens downtime in case of a leak. 

• Valve Packing Sets:

Steam boilers can operate even if the packing on a few valves is leaking, and tightening the snot out of the stem packing can stop the small leaks. However, valves do not function properly with over-tightened packing. Therefore, it is advisable to keep a spare packing set for all control valves. If a leak is unable to stop by snugging up the packing gland, it can be changed with the packing set out.

• Boiler Level Sight Glass:

It aids in identifying the correct amount of water in the steam boiler. Even a slight leak from the boiler sight glass or packing will impact the water level reading, resulting in unsafe operating conditions. It is crucial that the sight glass is clear and clean, and does not leak. If the sight glass becomes hard to read and is dirty, then it should be replaced. By having this boiler spare part, it can be changed easily should an issue arise.

• Observation Port Glass and Packing:

Process plants need to examine the flame during the operations. However, the observation port glass is often filthy, sooty, broken, leaking, extremely hot, or all of the above. Therefore, it is sensible to have a spare of it ready for such situations.

Conclusion:

Rakhoh Boilers is a leading boiler manufacturer in Pune since 1983. We manufacture a range of efficient steam boilers, waste heat recovery systems, thermic fluid heaters, and boiler accessories and provide excellent boiler services like steam trap assessment, boiler automation, energy audit, annual boiler maintenance, etc.

To learn more, visit www.rakhoh.com