Boiler Functional Problem and Solution:
Boiler functional and external problem and solutions are given below:
1. Safety Valve
Problem:
a. The safety valve set pressure exceeds the maximum allowable pressure of the boiler.
b. One or more safety valves are not functioning.
c. Drainage has not been installed on one or more safety valves.
d. Name plate of safety valve test pressure was not legible / name plates were covered in paint or scratched.
e. Name plate of safety valve test pressure was not legible / name plates were covered in paint or scratched.
f. Safety valve was found to be directly mounted on the boiler. Safety valve flanges are connected with inadequate nuts and bolts.
Solution:
a. The safety valve set pressure must be the same as the maximum allowable pressure of the boiler.
b. The non-functioning safety valve(s) must be serviced, repaired or replaced.
c. Drainage must be installed for all safety valves.
d. Boiler operator should make sure that name plates are permanently fixed onto the equipment and visible.
e. Boiler operator should make sure that name plates are permanently fixed onto the equipment and visible.
f. Confirm that safety valves are located in accordance with manufacturer's recommendations. Ensure that safety valve flanges are connected with all bolts and nuts.
2. Pressure monitoring
a. Pressure controller non-functional, no signal delivered to control panel.
b. Boiler Safety Valve outlet line is not directed outside of the boiler room.
c.No pressure monitoring system found.
d. The automatic power control of the burner is without function. The control is done manually by adjusting the air damper.
e. Burner control is done manually. Combustion air and gas pressure are not monitored. If the gas pressure fails, there is a risk of incomplete combustion and deflagration.
f.
Solution:
a. Pressure controller shall function as per manufacturer guideline.
b. Boiler Safety Valve outlet line should be redirected outside the boiler room.
c. Pressure monitoring system must be installed.
d. Install automatic pressure monitoring system and device for measurement and adjustment of fuel air ratio.
e. Install automatic pressure monitoring system and device for measurement of fuel gas flow.
3. Pressure gauge
a. There are no indication for pressure levels on the pressure gauge.
b. Steam pressure gauges are showing different pressure values.
c. The pressure gauge in the gas line was not functional.
d. Inadequate marking at pressure level gauge.
Solution:
a. Provide high-low level pressure indicators according to manufacturer's technical information.
b. Steam pressure gauges must be re-calibrated.
c. Repair or replace the pressure gauge.
d. The maximum allowable pressure of the boiler must be marked on the pressure gauge (red).
4. Steam pressure limiter
a. The function of the Steam Pressure limiter was not tested.
b. There are no high-level pressure indicators on the steam pressure limiter.
Solution:
a. The Steam Pressure limiter shall be functional to enable testing.
b. Provide high-level pressure indicators on the pressure limiter according to manufacturer's technical information.
5. Water Level Monitoring
a. There is no Low Low Water Level (LLWL) trip with interlock for the boiler.
b. One or more Low Low Water Level (LLWL) limiters are not working.
c. Low Low Water Level (LLWL) not marked at water level gauge.
d. Low Low Water Level (LLWL) trip is outside visible range of the water level indicator.
e. The controller for the second Low Water Level (LWL) indicator is missing in the cabinet.
f. The feed water pump off and high water level is not working.
Solution:
a. The Low Low Water Level (LLWL) tripping mechanism to be functional in accordance with wiring diagram.
b. All the limiters/controllers mounted on/installed with the boiler shall be functional.
c.The Low Low Water Level (LLWL) must be marked at the water level gauge.
d. Adjust and mark the Low Low Water Level (LLWL) within the water level indicator.
e. Water level controller for second Low Water Level (LWL) indicator to be installed in accordance with wiring diagram.
f. Repair or replace as necessary.
6. Leakage
During hydrostatic pressure test by using feed water pump, leakage was noted at the top of the boiler.
Solution:
Repair the water/steam leakage to the top of the boiler.
7. Pressure Limiter
a. Manual shut off present in line with the pressure limiter.
b. Pressure limiter settings on inlet/outlet of controller not interfaced automatically with burner control.
c. The maximum and minimum functions of the fuel pressure limiter are not indicated.
d. Pressure Limiter is missing.
Solution:
a. Manual shot-off device must be removed, and ball valve must be maintained in open position.
b. Installation to be in accordance with boiler manufacturer's information.
c. Provide fuel pressure limiter (maximum and minimum) indicators.
d. Pressure Limiter must be installed and kept functional.
8. Burner
During functional test Low Water Level (LWL) of the burner's OFF program was not functional
Solution:
Burner shall automatically shut down on indication of Low Water Level (LWL).
9. Electrical Wiring
a. Control panel cabinet does not specify the names of all boiler interlock alarm functions.
b. Non-compliant electrical cable connection.
c. No emergency stop button was available at the boiler cabinet or near the door outside the boiler room.
d. Burner operating door switch function was not satisfactory.
Solution:
a. Names of boiler interlock alarm functions must be specified in the cabinet.
b. For electrodes and solenoid valves electrical wiring must be separated and connected with nuts. Adequate cable glands must be used.
c. An emergency stop button must be installed at the boiler and outside the boiler room near the entrance door.
d. Burner operating door switch is required to be fully functional.
10. Fuel insertion
Fuel insertion system is manual.
Solution:
Ensure that relevant fire protection measures are taken (e.g. protection of operator against burns).
11. Fault alarm
There is no acoustic or optical alarm when the pressure limiter is activated.
Solution:
An acoustic or optical alarm should be installed.
12. Pressure switches
Pressure switches were not found to be in good/operational condition.
Solution:
Pressure switches must be repaired and re-calibrated or replaced.
13. Purging cycle
Purging duration was found short based on the boiler size.
Solution:
Purging cycle has to be set as per manufacturer recommendation.
14. Salt formation, scale formation
The boiler bottom hand holes were contaminated with foreign material (e.g. salt, scale).
Solution:
Tighten the hand holes and clean them. Maintain to avoid new build-up of foreign contaminants.
15. Handrail and ladder
Boiler handrail and ladder are inadequate.
Solution:
Provide suitable boiler handrail and ladder access.
16. Feed water pump
Feed water pump operation condition doesn't comply with safety regulations.
Solution:
Feed water pump shall be integrated so that pump will start automatically when the Low Water Level (LWL) is reached, even if the setting is off.
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