Boiler Emergencies

Procedures during the following emergency

conditions
1. Boiler Explosions
2. Boiler Implosions
3. Low Water Level
4. High Water Level
5. Boiler Tube Leaks
6. Master Fuel Trip

Boiler Emergencies
Emergency boiler procedures :
A) Boiler explosions
a. Causes
1. Furnace explosions can be caused by an accumulation of
unburned fuel in the furnace due to incomplete
combustion, loss of ignition, or fuel valve leakage.
2. With a mixture of unburned fuel with air in explosive
proportions, and the application of heat sufficient
enough to raise the temperature of the mixture to the
ignition point, explosions can occur.
3. The accumulated fuel is ignited resulting in a greater
than normal pressure increase.
4. The fuel may enter the furnace in the unburned state in
a number of ways, for instance:
a) Through leaky main fuel or ignition fuel inlet valves on
idle wind box/burner compartments.

Boiler Emergencies
b) If the fires are extinguished and if the fuel is not shutoff promptly.
c) If the fuel is not burning as rapidly as it is entering the
furnace.
d) In starting up, if difficulty is experienced in establishing ignition.
b. Prevention
1) During start-ups maintain a high air flow (up to 30% of full load air
flow) to ensure an air rich furnace atmosphere and prevent
accumulation of explosive mixtures.
2) Be sure that the main fuel and ignition fuel inlet valves on idle
fuel compartments or burners are closed tightly and do not leak.
It is advisable to remove idle oil guns from the guide pipes, to
avoid dripping.
3) Watch the fires so that the fuel may be shut off without delay if
extinguished unexpectedly. If the fires are lost, trip all main and
ignition fuel immediately. Close all trip and fuel shut off valves.
Purge the furnace at least for 5 minutes after shut down with 30%
(minimum) air flow.

Boiler Emergencies
4) When a boiler has been idle, purge the furnace before putting
igniters in service. Be sure that the warm up fuel firing rate is high
enough to produce a flame not easily extinguished.
5)Always use an associated igniter to light off a main oil or gas
nozzle.
6) Regularly check proper function of FSSS or BMS (interlocks,
trips)
B) Boiler Implosions : Destructive negative pressure.
a. Causes
1) Tripping or sudden loss of fuel results in mass temperature
reduction resulting in rapid decrease in furnace pressure.
2) Rapid evacuation of heated gases by ID fans.
3) Failure of fan controls.
b. Prevention
1) The air flow to the furnace must be maintained at its pre trip
value and must not be prevented from increasing by following
natural fan curves; but positive control action to increase air
flow is not allowed.

Boiler Emergencies water levels

2) The flow of combustion products from a furnace must be
reduced as quickly as possible following a unit trip.
3) If the removal of fuel from the furnace can be over a 5 to
10 seconds period (rather than instantaneously) there will be
a reduction in the magnitude of a furnace pressure excursion
that follows a unit trip.
4) Further prevention of implosion can be accomplished by
keeping protective control systems in proper working order
and well tuned.
C. Low Water Level
a. Causes
1. Control failure
2. BFP failure
3. Tube leaks
b. Action
1) Compare indication.

Boiler Emergencies- water levels

2) If the water level falls out of sight in the water gauge, due top
failure of the feed water supply or neglect of the operator, except in
cases of momentary fluctuations that might occur with extraordinary
changes in load, appropriate action should be taken at once to trip
the fuel. Any decision to continue to operate, even if only for a short
time at a reduced rating, would have to be made by someone in
authority who is thoroughly familiar with the circumstances that led
to the emergency and positively certain that the water level can be
restored immediately without damaging the boiler. In the absence of
such a decision :
a) Trip all fuel immediately.
b) Shut off all steam discharged from the unit( trip turbine, steam
driven auxiliaries etc.)
c) Simultaneously, if feed water has become available and the
operator is assured that no pressure parts have been damaged,
gradually reduce the flow of feed water to the boiler by manual
regulation. This will avoid quenching of hot pressure parts with
relatively cold water. The feed water regulating valve should be
closed completely when all the steam flow from the unit has
ceased.

Boiler Emergencies-water levels

d) Maintain a high air flow at first to hasten the cooling process.
e) If pressure parts damage is suspected, reduce the main steam
pressure gradually by opening the super heater startup drain. Open
the drum vents when the pressure drops below 1.75 bar. As the
boiler cools, reduce the air flow. Shut down the fans as soon as the
unit is cool enough for a man to enter. Drain the boiler when the
drum metal temperature is 93C. Determine the cause of low water
and examine the boiler for the effects of possible overheating such
as leaks and distortion of pressure parts.
D. High Water Level :Water impingement may cause turbine
damage.
a. Causes
1) Feedwater control malfunction
2) Operator error
b. Action
1) Abnormally high water level should be avoided as it may lead to
carryover and even priming. If the water level rises above rises
above the recommended normal operating range proceed as
follows

Boiler Emergencies-water levels

a) Reduce the water level immediately by opening the
intermittent
blowdown valves.
b) Reduce the steam rate, if necessary, and place
feedwater control on
manual.
2) If priming should occur, as indicated by rapid
fluctuations in outlet steam temperatures in outlet steam
temperature, proceed as follows:
a) Reduce the steaming rate.
b) If the water level is abnormally high, reduce the level
by opening the intermittent blowdown valves and
place feedwater control on manual.
c) Investigate the water condition (alkalinity and solids)
d) Investigate the condition of the drum internals as soon
as an opportunity is afforded.

Boiler Emergency-Tube failure

Boiler tube failures : Operating a boiler with a known tube
leak is not recommended. Steam or water escaping from a
small leak can cut other tubes by impingement and set up a
chain reaction of tube failures. By the loss of water or steam, a
tube failure can alter boiler circulation or flow and result in
other circuits being overheated. A tube leak can also cause
loss of ignition and, if reignition occurs, a furnace explosion. An
investigation of tube failure is very important so that the
conditions causing the tube failure can be eliminated and
future failures prevented.
The investigation should include a visual inspection of the
failed tube. In some cases a laboratory analysis or
consideration of background information leading up to the
tube failure is required. This information should include the
location of the failure, the length of time the unit has been in
operation, load conditions, start up and shutdown conditions,
and feed water treatment.

Boiler Emergencies-tube leaks

5.
a.
1)
2)
3)

Tube Leaks
Indications of the tube leaks are
Feedwater flow greater than steam flow
Excessive desuperheater flow
Wetted insulation of water running down casing with no
apparent cause.
4) Excessive make up.
5) Noise from the boiler (Acoustic noise level indicators)
b. Action
6) Furnace tube leaks
a) The action taken is dependant on the size and location
of the tube leak
1) A large leak may extinguish fire or cause loss of drum
level.
2) A medium size leak may force an immediate shut down.

Boiler Emergencies-tube leaks

3) A small leak may allow continued operation after considering
its consequences on continued operation.
b) If at all possible locate the leak
c) In the vent of failure of one or more water carrying tubes, the
best method of shutting down the unit will be dictated by the size
of the failure, the ability to maintain normal water level and the
demands for the service of the unit.
d) The following instructions regarding tube failures are of general
nature. It must be understood that conditions may arise which will
require exercise of judgment by the operators.
e) In case of a leak or tube failure which does not involve a
serious drain on the feedwater supply, the water level should be
maintained and the unit taken out of service in the normal
manner.
f) If the tube failure results in a loss of water so great that the
water level cannot be maintained with the feedwater supply
available, use the method outlined below.
1) Trip all fuel

Boiler Emergencies-tube leaks

2) Shut off feedwater to the boiler.
3) Maintain only enough air flow to carry the escaping steam up the
stack.
4) Leave the fans in service until pressure is off the unit.
g) After the unit has cooled enough to permit a man enter it, make a
thorough inspection of pressure parts for any indication of damage
resulting from loss of water level. After the necessary repairs have
been made, apply a hydrostatic test and obtain the approval of the
proper authorities before putting the unit back in service.
2) Economizer Tubes
a) An economizer tube leak can be detected by sound and/ or
increased make up water requirements. The leak should be
detected at the earliest possible time and the unit shutdown in the
normal manner.
b) Water leaks in the economizer can cause considerable erosion
damage to the adjacent tubes. Water carried over from
economizer tube leak may cause plugging of hoppers and
airheaters.

Boiler Emergencies-tube leaks

3) Super heater Tubes
a) A small leak in a superheater element should be investigated
at the earliest possible time, and the unit should be shut down in
a normal manner. Steam leaks in the superheater can cause
considerable erosion damage to the adjacent tubes. Any decision
to continue operation with leaks should be made this in mind.
b) A major superheater tube failure may require an emergency
unit shutdown.
6. Master Fuel Trip
a) Under conditions requiring a master fuel trip through normal
interlocks or operators action (manual trip), all fuel should be
tripped instantaneously.
b) The following steps should be taken immediately following an
emergency fuel trip.
1) Maintain the unit air flow at the pre-trip value for at least 5
minutes to purge the system.
2) Check to ensure that all the fuel nozzles shut off valves are
closed.

Boiler Emergencies-tube leaks

3) If all auxiliary power sources are lost during a trip, upon
restoration of power, start the ID and FD fans and purge
the furnace for five minutes.
Other boiler emergencies
Air preheater fires/tripping of APH ( one fan operation)
Coal mill explosions ( may lead to boiler trip)
Loss of furnace seal
Loss of scan supply of any elevation
Loss of instrument air
Loss of cooling water to scaffold door
Bending of long retractable soot blower / furnace probe

BOILER TRIP Causes

With the exception of the operator push button trip, following conditions
will automatically generate Master Fuel Trip (MFT)
Loss Of All ID Fans
Loss Of All FD Fans
Less Than Two Circulating Pumps Running
Circulating p Less Than 0.6 Bar
Drum Level Low-low (-330 mm).
Furnace Pressure More Than 330 Mmwc Or Less Than -250 Mmwc
Loss Of All Fuel
Air Flow Less Than 30%
Turbine Trip
Reheater Protection Trip
Unit Flame Failure
Loss Of Unit Logic Power
Emergency Push Button.
Cause of trip system : The first boiler trip command that causes a MFT
will illuminate the appropriate indicator in the cause of trip section on the
console insert. Any successive boiler trip commands to the other indicators
are blocked. There will be only one indicator that will be glowing