SAFE OPERATION OF THE

BOILERS
What is safe operation of Boilers ?

• Safe operation of Boiler means boiler

should run without any trouble with all
designed parameters/efficiency on
specified running hours.
 Unsafe Operation of Boiler lead to
following
• Loss of Production.
• Loss of fuel (Criminal loss as fuel cost
increasing day by day)
• Damage to Plant /Equipments/Buildings
• Loss/Injury of Human working nearby.
• Loss of Down Time of Industry.
• Deteriorate efficiency.
• Reduce Life of Boiler..
Factor Affects for Safe
Operation of Boiler
Operation
 Operation
• Regular Log of All Parameters, hourly, daily,
weekly, fortnightly, monthly and annually.
• All operating limits are to be checked and
simulated periodically.
• Operating instructions are to be followed strictly
as per supplier’s recommendations.
• Regular checking of water treatment procedure,
analysis of Boiler water and Steam.
• Proper Communication system to be adopted to
avoid any wrong interpretation.
• Boiler is not to be operated continuously above
rated parameters.
Operation
Operation

Competence
 Competence
• Required competent persons to be recruited at
different level from operator to the manager for
safe operation of boiler.
• Assessment of the competence of the
maintenance staff to be done.
• Only certified operators, engineers are to be
allowed for boiler operation and maintenance.
• Regular training and development program to be
organized in house or at out side agency to build
up competency level for safe operation.
Operation

Competence

Training
 Training
• The training for all operating staff must be appropriate for
the equipment they will operate.
• The level of competence and training must be review
when a system is modified or changed.
• The training is delivered by people who have appropriate
knowledge on assessment skill on their specific boilers
and equipments.
• Trainers have enough industrial experience to put the
information in the right context and knowledge for the
working environment in which the trainee is expected to
work.
• Latest technological tools to be used for appropriate
required training at shop floor and simulators.
Training
Operation

Competence

Training

Maintenance
 Maintenance
• Maintenance procedure to be lay down and
followed strictly for all equipments.
• Pro active, predictive, preventive, annual, routine
maintenance to be done for safe operation of the
boiler.
• All required spares / tools / equipments to be
kept in boiler house.
• Repair or modification in the system to be done
in accordance with manufacturers, supplier and
authorized regulatory for pressure parts.
Operation

Competence

Training

Maintenance

Design
 Design
• Design of the boilers should be checked for all
safety measures taken in to considerations for
safe operation.
• All the equipments are to be design to take care
for worst conditions of the operation.
• Boilers are to be designed for maximum
automatic alarm, shut off, interlocking &
protection devices.
• All Boilers are to be designed as per specific
requirement of End Use of steam parameters i.e.
Pressure, Temperature & Flow.
Operation

Competence

Training

Maintenance

Design

Location
 Location
• Boiler is to be installed at proper location
to avoid from nearby unsafe areas like
chemicals, fumes, hazardous wastes, fire
etc.
• Approaches and openings for removal in
case of any emergency to be kept in
consideration for suitable location of boiler.
Operation

Competence

Training

Maintenance

Design

Location
Safety
System
 Safety Systems
• Alarms and automatic shut off boiler in
case of any abnormal condition during
operation of boiler.
• Periodic checking to be done of all safety
devices or systems installed / equipped
with the boiler.
• Safety training programs to be introduce to
aware of the safety devices and systems.
 Operation

Competence

Training

Maintenance

Design

Control
Location
System
Safety
System
 Control Systems
• All control systems are periodically
checked for healthy and safe operation.
• Any changes in the control system to be
done as per suppliers or manufacturers
recommendations.
• Alternate Power Source for control
systems are to be taken into consideration
Like Battery Back up, UPS, Invertors etc.
 Operation

Competence

Training

Maintenance

Testing Design

Control
Location
System
Safety
System
 Testing
• Standard testing procedure is to be adopted for
safe operation as per supplier’s/manufacturer’s
recommendations.
• Periodic testing of safety valves to be done to
check freeness and to avoid any incidents of
unsafe operation.
• Procedure for testing to be laid down clear cut in
written & strictly followed as per Boiler
regulations.
• Routine testing of boiler controls, limiting devices
and feed water quality is essential to ensure the
boiler continues to be safe, reliable and efficient.
 Operation

Competence

Super Vision Training

Examination Maintenance

Testing Design

Control
Location
System
Safety
System
 Examination & Supervision
• Scheme of examination for all relevant pressure
system falls under Boiler Regulations is a legal
requirement which take cares from
manufacturing, installation and safe operation of
any boiler.
• Periodic specified examination of every boiler
during operation is to be done by government
boiler directorates and competent authorities.
• Examinations and supervision is helping the
owner / user to establish the safe operating
limits of a pressure system.
 Operation
Management Competence

Super Vision Training

Examination Maintenance

Testing Design

Control
Location
System
Safety
System
 Management
• Proper selection of boiler before ordering.
• Installation from competent contractors.
• Required periodic examination from
competent and authorized person to be
done.
 Operation
Management Competence

Super Vision Training

Examination Maintenance

Testing Design

Control
Location
System
Safety
System
BOILER EMERGENCY
OPERATIONS
BOILER EMERGENCIES –
Various Emergency
situations during operation with a special emphasis on the
safety aspect like boiler protection systems controls and
interlocks.
1. Drum level low and low-low
2. Drum level high and high high
3. Furnace Draft high and high high
4. Bed Temperature High
5. Bed Temperature Low
6. Water wall / screen tube / evaporator tube failure
7. Super heater tube failure
8. High super heater temperature
9. Low Super heater temperature
10. Flame Failure
11. Furnace Explosion
12. Boiler pressure high
13. Coal feeder failure
14. PAH / SAH tube failure
15. Boiler feed pump failure
16. Fan Failure 32
1. DRUM LEVEL LOW AND LOW-LOW:-
(A) CAUSE :-
1. Failure of boiler feed pump.
2. Failure of drum level controller.
3. Inadvertent opening of C.B.D.
4. Extraordinary change in load. (Sudden reduction in load)
5. Water tube failure.
(B) EFFECT :-
1. Boiler may damage badly.
(C) ACTION :-
1. Run the boiler if drum level is within safe limit (Lo alarm and lo-lo alarm
came). If it goes beyond safe limit allow boiler to trip.
1a. Attempt to control with feed valve.
1b. If feed valve is stuck up open parallel line valve or bypass valve.
1c. Take care while increasing feed flow that running B.F.P. do not trip on feed
flow high.
1d. If low level is due to tripping of feed pump start stand by pump, if it is on
manual.
2. If water level is below safe level, allow to trip the boiler on drum level lo-lo
to protect the boiler drum and tubes.
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2. DRUM LEVEL HIGH AND HIGH HIGH :-
(A) CAUSE
1. Failure of drum level controller.
2. Extra ordinary increase in load
3. Sudden increase in firing rate.
(B) EFFECT:-
1. Water may enter turbine and serious damages to turbine may occur.
2. Joint valve on main steam pipe work leaks.
3. Carry over with sharp fall in super heater temperature
(C) ACTION :-
1. Run the boiler if drum level is within safe limit (drum level high and high high alarm
came). If goes beyond limit allow boiler to trip.
• Attempt to control with feed valve.
• If feed valve is stuck up close isolating valve.
• Attempt to control drum level by opening C.B.D.
• Close Economizer inlet valve and allow feed pump to run in recirculation.
• If above measures fail trip the feed pump.
2. If level is due to sudden rise in load. If high level rises above normal level allow boiler
to trip on drum level high high.
• If main steam temperature drop takes place open steam pipe drains.
• Trip the turbine / prime mover when steam
temperature falls. 34
3. FURNACE DRAFT HIGH AND HIGH HIGH
(A) CAUSE :-
1. Due to faulty operation of fan control.
2. Disturbed combustion
3. Un-controlled fuel entry
(B) EFFECT:-
1. Boiler may damage due to high furnace pressure.
2. Weak parts of furnace (ductings and enclosures) may
explode due to high furnace pressure.
(C) ACTION :-
1. If it is due to faulty operation of I.D./P.A./S.A. fan control,
take it on manual and maintain the furnace in suction.
2. If furnace pressure has increased beyond limit allow boiler
to trip on furnace draught high high. 35
 4. BED TEMP. HIGH :-
(A) CAUSE :-
1. High CV and low ash coal used.
2. Low P.A. flow / S.A. flow
3. Sudden change in load
4. Faulty bed temp thermocouple
5. Ash recirculating system trouble
(B) EFFECT :-
1. Chances of clinker formation
2. Chances of refractory failure
3. Chances of screen tube failure
(C) ACTION :-
1. Control bed temp by recirculation ash through recirculation feeder.
2. Start sand feeder if bed height permits.
3. Increase P.A. flow up and increase S.A. flow.
4. Reduce the load by cutting coal feeder.
5. Coal feeders trip, if temp rises above limit and allow boiler to trip, if temp exceeds beyond
safe limit to save bed from clinkerisation.
36
6. Check the bed temp thermocouple.
 5. BED TEMP LOW :-
(A) CAUSE :-
1. High PA with respect to load / high SA flow w.r.t. load.
2. Low CV high ash coal used.
3. Coal interruption or coal feeder trips or overfeeding of coal into furnace.
4. Recirculation ash feeder speed may increase.
5. Faulty bed temp. thermocouple.
6. Water tube / screen tube / evaporator tube failure.
(B) EFFECT :-
1. Boiler steam flow will reduce.
2. Super heater temp drops.
3. Furnace draft will fluctuate.
(C) ACTION :-
1. Reduce P.A. Fan flow, if excessive / reduce S.A. flow, if excessive.
2. Reduce speed of recirculation ash feeder.
3. Stop bed material supply, if running.
4. Check bed temp thermocouple.
5. Check any leakage sound from furnace. 37
6. Check coal feeder and coal supply.
6. WATER WALL / SCREEN TUBE /
EVAPORATOR TUBE FAILURE
(A) CAUSE :-
1. Starved water wall.
2. Block tube, eroded tube, pitted tube, salt deposits.
3. Circulation affected due to open low point drains.
(B) EFFECT :-
1. Hissing steam leakage noise from boiler.
2. Unstable flame fluctuating draught.
3. Bed temperature drops sharply.
4. High feed water flow for given steam generation / increase in make up water.
5. Increase in I.D. Fan loading.
6. Below screen temperature drops sharply.
7. Flue gas outlet temperature decreased.
(C) ACTION :-
1. Every shift check low point drain valve are fully closed.
2. Every shift check the furnace listen furnace to detect steam noise.
3. At first diagnostics of tube failure, start load reduction; trip out unit before damage become
serious. Quicker shutdown reduces extensive damage.
4. Try to locate tube at low level.
5. Don’t allow the drum level to go beyond a danger level.
6. Start another BFP, if drum level is not maintained by running BFP. 38
 7. SUPER HEATER TUBE FAILURE :-
(A) CAUSE :-

1. Sustaining high metal temp due to water wall slagging or inadequate steam flow
and high gas temp during hot start.
2. Erosion on tubes due to high excess air.
3. Blocked tubes.
4. Starvation of tubes.
5. Salt deposition due to high water level in drum. Poor quality of spray water.
(B) EFFECT :-
• Hissing noise notices.
• Flue gas temp drops.
• High feed water consumption compared to steam flow.
• Over loading on I.D. Fan.
• Erosion of other tubes and damages to other SAH tubes.
(C) ACTION :-
1. As soon as leakages noticed start reducing the load and trip the boiler.
2. Listen the SH region for steam leakage.
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3. Try to locate leakage through manholes before the boiler is depressurized.
8. HIGH SUPER HEATER TEMP
(A) CAUSE :-
1. High excess air.
2. Low feed water temp HP Heater not in service at constant firing /
load.
3. Sudden increase in firing rate to increase steam pressure.
4. In adequate spray.
5. Lodging of soot on the water walls considerably.
(B) EFFECT :-
Rise in (+ve) positive turbine expansion.
1. Creep rate increase in tube metal, turbine parts, steam piping.
(C) ACTION :-
1. Check feed water temp. If HP heaters are available, put in service and if
not reduce the load.
2. Slow down firing rate.
3. Reduce excess air, if more.
4. Check Spray control 40
 9. LOW SUPER HEATER TEMP. :-
(A) CAUSE :-
1. Dirty super heater
2. Inadequate air flow.
3. High Spray
4. Too high feed water temp.
5. Sharp increase in load and pressure drop.
6. High Drum level.
(B) EFFECT :-
1. Turbine expansion may be negative.
2. May induce thermal stresses in S.H.
(C) ACTION :-
1. Check air flow – increase, if necessary.
2. Reduce spray, if more.
3. Check feed water temp.
4. Avoid sharp rise in load to boiler pressure drop.
5. If, it is due to high drum level – allow unit to trip and open main steam drains.
41
 10. FLAME FAILURE :-
(A) CAUSE :-
1. Dirty Oil / Gas Burner
2. Faulty Flame Scanner
3. Failure of Blower
4. Furnace Pressure High
5. Low Combustion Air
(B) EFFECT :-
1. Boiler will trip on flame failure
2. Chances of furnace explosion, if unburnt oil / gas / coal mixture entered in furnace.
3. Boiler steam pressure may fall down.
4. Super Heater Steam Temp. drop sharply.
5. Variation observed in drum level.
(drum level low)
(C) ACTION :-
1. Purge the boiler before putting burner back and purge burner as per cycle time given by supplier.
2. Check the flame scanner and clean the photocell, if found dirty.
3. Check the sparking circuit and high voltage transformer supply.
4. Check spark plug, if found dirty, clean it and set the gap.
5. Clean the burner tip, if nozzles (holes) are found chocked.
6. Check the air blower and maintain air fuel ratio.
7. Check the explosion doors, close it if opened. 42
11. FURNACE EXPLOSION
(A) CAUSE :-
1. Accumulation of unburnt fuel during lit up / start up of
boiler.
2. Improper burning.
3. Inadequate air.
4. Secondary combustion.
(B) EFFECT :-
1. Furnace explosion can cause extensive damage.
(C) ACTION :-
1. Always purge the boiler with 40% full load air for about
five minutes. No cut short in purging allowed.
2. Adjust fuel air ratio.
43
OVERVIEW OF UTILITY
BOILER
OVERVIEW OF UTILITY BOILER
PHOTOGRAPHS OF BOILER
AFTER EXPLOSION
PHOTOGRAPHS OF BOILER
AFTER EXPLOSION
PHOTOGRAPHS OF BOILER
AFTER EXPLOSION
PHOTOGRAPHS OF BOILER
AFTER EXPLOSION
12. BOILER PRESSURE HIGH
(A) CAUSE :-
1. Sudden drop in load / steam flow.
2. Un-controlled fuel entry.
3. Turbine / prime mover trips.
(B) EFFECT :-
1. Disturbance in drum water level.
2. Safety valves may life if pressure rise is up to that extent.
3. Boiler may trip on high pressure.
(C) ACTION :-
1. Open start up vent valve.
2. Control fuel input and drum level.
3. Check coal feeder feeding rate.
4. Adjust the load on unit, if it has dropped.
5. If TG / prime mover has tripped first, allow boiler to trip but
safety valve may lift. 50
 13. COAL FEEDER FAILURE :-
(A) CAUSE :-
1. Electrical supply failed
2. V.F.D. fault
3. Bed temperature high
4. Furnace draft high
5. Furnace draft low
6. Drum level high
7. Drum level low
(B) EFFECT :-
1. Boiler pressure may fall down
2. SH steam temp fall sharply.
3. Bed temp. will decrease.
4. Variation in furnace pressure (LOW)
5. Variation in drum level (Low)
(C) ACTION :-
1. Control boiler pressure by reducing load on turbine / prime mover or process.
2. Control super heater steam temp by closing spray valve.
3. Reduce PA / SA flow to control bed temp.
4. Control furnace draft and drum level.
5. Check electrical fault or emergency stop push button & restart coal feeder.
6. Check VFD fault, if any.
51
7. Restart coal feeder after checking cause of failure.
 14. PAH / SAH TUBE FAILURE
(A) CAUSE :-
1. Erosion of tube.
2. Corrosion of tube.
(B) EFFECT :-
1. Flue gas temp after APH will fall down.
2. Increases in O2 percentage at ESP inlet.
3. PA / SA Fan overloaded.
4. Bed temp may be increased.
(C) ACTION :-
1. Control flue gas temp by passes PAH.
2. Reduce coal feeding to maintain O2 percentage.
3. Control bed temp.
4. If leakage of tubes are more stop the boiler
and plug / replaced.

52
15. BOILER FEED PUMP FAILURE :-
(A) CAUSE :-
1. Motor protection relay operates
2. Lube oil temperature high
3. Discharge flow high
4. Motor bearing temperature high
5. Deaerator level low
6. BFP suction pressure low
(B) EFFECT :-
1. If standby pump is available, it will start on auto or start it manually.
2. If standby pump does not start on auto & manual, drum level may go very low, which may
trip the boiler.
(C) ACTION :-
1. Start the stand by pump, if it does not start on auto. Adjust the load to maintain the drum
level as well as to prevent the tripping of this pump on high feed water flow.
2. See the proper operation of recirculation valve and C.W. Valve.
3. Analyze and rectify the fault in the main feed pump. Put it on auto.
4. Restore the bus supply, if it has lost and make the pump available.
5. Check the deaerator level and if it falls below safe limit, stop the feed pump, immediately.
6. Check the BFP suction strainer and clean it, if found chocked.
53
 16. LOSS OF FANS
(1) ID FAN FAILURE

(A) CAUSE :-
1. Electrical motor protection
2. Fan bearing temp becomes high high
3. Motor bearing temp becomes very high
4. Drive fault (MCC fault)
5. Boiler trip
(B) EFFECT :-
1. Furnace may get pressurized
2. Boiler will trip on boiler furnace pressure high.
(C) ACTION :-
1. Check emergency or field stop.
2. Rectify electrical fault, if any.
3. Check cause for boiler trip & normalize it.
4. Check fan / motor-bearing temp.
5. Restart I.D. Fan after checking cause of tripping and taking corrective54
actions.
 (2) P.A. FAN FAILURE :-
(A) CAUSE :-
1. Electrical motor protection.
2. Fan bearing temp. becomes high high.
3. Motor bearing temp. becomes very high.
4. MCC fault.
5. Boiler trip.
6. Run feed back off.
7. ID Fan trip.
8. SA trip.
(B) EFFECT :-
1. Boiler will trip on
a. Furnace draft low
b. P.A. flow low.
(C) ACTION :-
1. Rectify electrical fault, if any.
2. Check cause for boiler trip and normalize it.
3. Check fan / motor-bearing temp.
4. Restart the P.A. Fan after checking the cause of tripping and 55
taking corrective actions.
 (3) S.A. FAN FAILURE:-
(A) CAUSE :-
1. Electrical motor protection.
2. Fan bearing temp becomes high high.
3. Motor bearing temp becomes very high.
4. MCC fault.
5. Boiler trip.
6. Run feed back off.
7. I.D. Fan trip.
(B) EFFECT :-
1. Boiler will trip on low furnace draft.
(C) ACTIONS :-
1. Rectify electrical fault, if any.
2. Check cause for boiler, trip & normalize it.
3. Check fan / motor-bearing temp.
4. Restart the S.A. Fan after checking the cause of tripping
56
and taking corrective actions.
THANKS
57