Boiler Internal Problem and Solution
All boiler internal problem and solution they must follow the manufacturer guideline.
There are 50 boiler internal problem and solutions are given bellow:
1. Leakage:
Problem:
a. The boiler blowdown valve was found to be leaking.
b. Leakage was observed in the level transmitter nipple.
c. Leakage was observed in the welding of the dummy flange nipple.
d. Leakage was found in the feed water suction line.
e. Leakage found in boiler outlet valve.
f. Leakage found in main steam valve and valve in common header.
g. A droplet was observed in the water level gauge glass.
h. Gasket leakages were observed: nipple leakage on top of the boiler, in handhole and manhole.
i. Gas leakage was observed in two joints of the gas line piping.
Solution:
a. The blowdown or drain valve must be replaced.
b. Level transmitter nipple must be tightened.
c. Repair the leakage.
d. Repair the leakage of the feed water suction line.
e. Leakage must be repaired at boiler outlet valve. Ball valve should not be used for boiler steam outlet line.
f. Any leakage in steam valves must be stopped to prevent back steam pressure.
g. The water level gauge glass must be tightened.
h. Replace the defect gaskets.
i. Boiler operator to address leakage and replace/repair as necessary.
2. Refractory lining
Problem:
a. The refractory lining close to burner has defects.
Solution:
a. The lining should be renewed.
3. Safety valve
Problem:
a. Safety valve outlet and vent line are not projected to the boiler room outlet.
b. Safety valve was found to be mounted using a tee joint or mounted on the manhole door.
Solution:
a. Safety valve outlet and vent line must be extended outside of the boiler room.
b. Safety valves must be mounted directly onto the boiler shell.
4. Discharge pump
Problem:
a. During the functional test the discharge pump showed insufficient flow.
Solution:
a. Boiler discharge pump is required to be functional according to manufacturer's guideline.
5. Corrosion
Problem:
a. Inside of the boiler was found to be corroded due to raw water supply.
Solution:
a. Boiler water must be external or internal treated one. Boiler operator should operate the boiler with proper blow down. Avoid the rapid boiler water heating in order to achieve the boiling temperature. Shell thickness and water side bottom end plate thickness are required to be verified and compared with relevant boiler specification.
6. Water drainage
Problem:
a. Inadequate drainage provided from boiler room.
Solution:
a. Provide a appropriate drainage system serving the boiler room, directed externally.
7. Burner
Problem:
a. Rapid boiling of water at the start of boiler operation.
b. Carbon deposition was found in the burner.
Solution:
a. Provide preventative measures to avoid rapid heating of water in order to reach required temperature.
b. Clean the fuel oil injector periodically.
8. Damaged refractory
Problem:
a. Refractory was found damaged in combustion chamber.
Solution:
a. Repair the refractory in combustion chamber.
9. Feed water quality
Problem:
a. The boiler's feed water quality does not comply with the standards.
Solution:
a. Feed and boiler water quality and conditioning must be verified and monitored. Water TDS, pH value to be maintained as per international or BBR standard to achieve required water quality.
10. Flame monitoring system
Problem:
a. There is no visual flame monitoring system in place.
Solution:
a. A visual flame monitoring system is required to be installed.
11. Flue gas path
Problem:
a. Flue gas path outlet is not open, flue gas path cannot be observed.
Solution:
a. Provide suitable access to confirm flue gas path.
12. Pressure gauge
Problem:
a. Boiler pressure gauge range too low.
Solution:
a. Boiler pressure gauge range should be twice the boiler's maximum allowable working pressure. Provide appropriate steam pressure gauge for this boiler.
13. Water Level Monitiring
Problem:
a. Water level gauge has no marks for Low Water Level (LWL), Low Low Water Level (LLWL) and High Water Level (HWL).
Solution:
a. Low Water Level (LWL), Low Low Water Level (LLWL) and High Water Level (HWL) must be marked in the water level gauge.
14. Mounting to foundation
Problem:
a. Boiler was found not properly mounted to the base.
b. Foundation of boiler and boiler accessories is inadequate.
Solution:
a. Boiler must be properly mounted to the base according to manufacturer's recommendations.
b. Proper bolt and support to be provided for all foundation as per manufacturer drawing.
15. Salt formation, scale formation
Problem:
a. Salt and scale formation was observed on the water side.
b. Hard scale found in the level transmitter rod.
Solution:
a. Cleaning is required. A water treatment station is to be used and feed and boiler water quality and conditioning must be verified and monitored. The boiler operator should operate the boiler with proper blowdown.
b. Measuring and functional equipment must be cleaned periodically.
16. Soot formation
Problem:
a. On flue gas side, soot deposition was observed in the furnace as well as inside the fire tube.
Solution:
a. Clean the furnace and inside of the fire tube periodically using air, to prevent excessive soot build-up.
17. Support to pipeline
Problem:
a. The feed water pipeline was found to be lacking proper support.
Solution:
a. Ensure proper support for the feed water pipeline.
18. Water level gauge
Problem:
a. The water level gauge glass is not protected.
b. Water level gauge vent line was not directed to boiler room outlet.
Solution:
a. Water level gauge glass must be properly protected with proper rod or covered by suitable rectangular protection glasses.
b. Water level gauge vent line should be projected to boiler room outlet.
19. Pipeline routing
Problem:
a. The blowdown outlet pipeline was found to be routed incorrectly (in an upward slope).
Solution:
a. Discuss re-routing with manufacturer.
20. Exhaust gas inlet backplate inspection door
Problem:
a. The exhaust gas inlet backplate inspection door is missing.
Solution:
a. The inspection door must be installed according to the manufacturer's specifications.
21. Carbon deposition
Problem:
a. Carbon deposition was found in the water tube.
Solution:
a. Install the fuel burner according to the manufacturer's instructions.
22. Improper welding
Problem:
a. Improper welding found between flange and manhole stub joint on the top of the boiler as well as other erection joints.
b. Nozzles have no welded joints on the water side.
Solution:
a. Welding must be rectified by a qualified welder.
b. Suitable welded joints to be provided in order to maintain boiler safety and operational life expectancy.
23. Flue gas path
Problem:
a. Carbon deposition was found in the flue gas path and fire path.
Solution:
a. Maintain the proper air-fuel ratio as per the manufacturer's data. Clean the flue gas and fire path periodically.
23. Flange thickness
Problem:
a. Top of the flange thickness does not match boiler's specifications.
Solution:
a. Carry out a thickness survey and confirm with manufacturer's data.
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