Factors to Consider and Tips for Steam Boiler Replacement

Factors to Consider for Steam Boiler Replacement:

While considering boiler replacement, it is prudent to assess three important factors- Safety, Economic, and Requirement Changes

Safety Changes:

Safety issues are usually detected during regular inspections as the inspectors check the condition of pressure vessels and boiler safety equipment. Along with a regular examination of steam boilers, it is necessary to monitor the process operations.

Excess Cycling:

Consistent starting and shutting off steam boilers increases the thermal cycles that impact the pressure vessel. Fatigue in boiler steel is caused due to excess thermal cycles and resultant stress.

High Stack Temperature:

Stack temperature exceeding the normal level indicates poor heat transfer and hazardous conditions due to poor water quality, improper combustion, and low water levels.

Improper Starting and Shutting:

Irregular starting and shutting indicate the improper functioning of the operating and safety controls of the steam boiler.

Poor Combustion Tuning: 

Error in fuel and airflow leads to pulsations and surging. It is usually caused by problems in the combustion fan, improper burner adjustment, improper stack design, and conditions. 

Safety issues in steam boilers generally occur as waterside issues or fireside/combustion side issues. In most cases, issues in waterside are caused by poor water treatment that includes,

Water Hardness:

Scaling develops on the steam boiler tubes due to the absence of a water softener or improper water treatment. The scale formation hinders the heat transfer and results in overheating.

Poor Water Chemistry:

Lack of water chemistry control leads to caustic embrittlement that causes tubes to lose their vital mechanical properties.

Presence of Oxygen:

Improper water treatment system leads to oxygen pitting on the surface of the tube that consequently leads to corrosion.

Quenching:

• Inappropriate water circulation leads to overheating specific areas of the steam boiler. The sudden cooling of overheated steel develops cracks that result in boiler failure.
• Fireside or combustion side safety issues are caused by poor tuning or fuel and air issues. It includes,

Improper tuning: 

Improper tuning leads to improper combustion and carbon deposits.

Outdated control equipment:

Outdated controls result in poor air and fuel control

Unsafe operating controls and safety equipment:

It includes unreliable flame scanners, safety relief valves, pressure and temperature switches, etc.

Economic Changes:

Reduced efficiency in steam boilers is a significant reason to consider boiler replacement. That is because inefficiency in the boiler leads to acceleration in fuel costs and operating hours. Therefore, improvements towards the efficiency of the steam boiler can considerably save the costs of the processing facilities. Along with it, consideration of the extent of reparation determines the need for boiler replacement. Sometimes, the cost of repairing can be expensive enough that boiler replacement would be a better alternative. 

Requirement Changes:

Advancement in technology and steam boiler design indicates that investing in boiler replacement would be a wise decision in the long run. An oversized boiler operating in a low range and occupying the majority of space is less desirable than boiler systems that are optimal for the load requirement. Such boilers can substantially reduce the excess costs and provide enhanced efficiency and performance. Plant managers can consult expert boiler manufacturers to understand their processing unit requirements.

These considerations must be given due attention before deciding on boiler replacement. Along with it, current and future plant loads should also be considered before replacing the boiler system.

Tips for Boiler Replacement:

• Ensure Proper Boiler Size as per the Requirement of the Processing Plant
• Load should be Optimal to Boiler Size and Design
• Examine the Main Piping for Insulation
• Determine the height of Water Level
• Heat the Boiler but Avoid Steam Generation during Start-Up
• Adjust Pressure Control Properly
• Draw a Mark on Gauge Glass
• Ensure Regular Maintenance of Steam Boiler
• Proper Training to Operating Personnel for Handling and Operating the Boiler System

Conclusion:

Rakhoh Boilers is a trusted boiler manufacturer in Pune since 1983. With 38+ years of experience and expertise in thermal solutions, we deliver highly efficient and reliable industrial steam boilers, waste heat recovery systems, thermic fluid heaters, and boiler accessories to over 20 process industries in 26 countries worldwide. We provide excellent boiler services to boost the efficiency and productivity of the boilers.

Visit www.rakhoh.com for more details on our products and services