Professional Documents
Culture Documents
Boiler Safety
Boiler Safety
Important Points
Heating Surface :
That side of the boiler surface exposed to the products of combustion,
exclusive of super-heating surface.The areas to be considered for this
purpose are tubes, fire-boxes, shells, tube sheets & the projected area
of the headers.
Sequence of Safety valves Blowing:
The super-heater safety valves should always be set at a lower
pressure than the drum safety valve ,so as to ensure steam flow
through the super-heater at all times. If the drum safety valve blows
first, the super-heater could be starved of cooling steam, leading to
possible super-heater tube overheating & rupture.
Important Points
Re-heater Safety valves :
The capacity of re-heater safety valves can not be included in the total
safety valve capacity required for the boiler & super-heater.The
relieving capacity of re-heater safety valve must not be less than 15 %
of the required total on the header. The total capacity on the re-heater
must be at least equal to the maximum steam flow for which the reheater is designed . One SV must be on the re-heater outlet.
Installation of Safety valves:
Every safety valve shall be connected so as to stand in an up-right
position with spindle vertical.
Boiler operating floor was full of coal / ash/ dust and even the local BMS
panel was fully covered with dust.
BMS panel was never used for operating the trip valves
Flame scanners were inoperative for many years and also the igniters were
Non-functional.
Boiler furnace corners 1 & 4 got completely ripped open above CD elevation up to the
furnace top.
ii)
Front and left water walls got bulged outward and the buck-stays were damaged.
iii)
Economiser duct from the boiler bank outlet up to the economiser opened out and had
blown .
Contd
ii)
Flame failure was not detected since the flame scanners were not in operation.
iii)
Due to sudden grid fluctuation, the boiler tripped on loss of air flow protection.
iv)
v)
vi)
Situation further aggravated inside the furnace since the draft fans were also not
available.
vii) The fuel oil supply continued to go inside the furnace since the fuel oil pumps were
on station supply and the oil trip valves could not be closed manually causing boiler
explosion.
iii)
Practice of operating the fuel trip valves by shorting of the contacts should be
dispensed with.
All the boiler auto controls should be made functional and must be maintained.
iv)
The DC battery and other connected system should be maintained in perfect condition.
v)
All the interlocks of auxiliaries like FD fans, ID fans, etc should be made operative. The
flame scanners and igniters are also to be made operational.
contd
The use of oil should be discontinued beyond 40% unit load and stable operation
should be achieved with coal firing after 40% load.