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ME101
Expulsion from the Safety Valve of D rum Due to Blockage of the
#2 Boiler Superheater Needle Valve
Technical committee

Expulsion from the safety valve of drum due to blockage of the #2 boiler superheater needle valve
(Boiler MDM-901)

1. Outline of breakdown

After entering dock at Malaysia’s MSE and completing Docking work, the ship once again set sail in
order to carry out sea trials.
While carrying out ballasting (operation of 2 cargo pumps) and after repeatedly increasing and de-
creasing the main engine speed for about 2.5 hours, the main engine speed was set to 50 rpm. At this
time, the boiler was operated with AS-22 x 3 units at oil pressure 17kg/cm². By an order from the
bridge, the speed was increased to 55 rpm. Due to a rise of boiler load, the #4 burner ignited. Immedi-
ately afterward, the oil pressure increased to 20kg/cm², the #2 boiler drum pressure rapidly increased,
and finally resulted in expulsion from the safety valve of drum.
The main engine speed was immediately reduced and anchor was let go at Johol – Anchorage for
safety reasons.
The following day, with assistance from the dock workers, various inspections were carried out to as-
certain the cause of this breakdown. As blockage of the #2 boiler superheater needle valve was as-
sumed, this boiler was stopped and overhaul inspection of the needle valve was carried out. Investiga-
tion revealed that the superheater hand hole plug was caught which caused blockage.

2. Causes

The hand hole plug which was left inside the superheater header was pushed toward the needle valve
due to the flow of steam during operation. This caused blockage of the valve.

3. Countermeasures

Recently, as the docking period is short, especially with regard to turbine vessels, the later half of the
docking period becomes very busy and there always seem to be a shortage of workers. Moreover, at
overseas docking yard, worker carry out which exceeds what we would consider to be reasonable be-
havior seems to take place without second thought. As work continues late into the night, sufficient
wariness is required. Therefore, when docking at overseas, it is important to formulate a plan of action
when trading spare parts for supplies.