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Boiler Top 50 Internal problem and Solution

Boiler Internal Problem and Solution
All boiler internal problem and solution they must follow the manufacturer guideline.

There are 50 boiler internal problem and solutions are given bellow:

1. Leakage:

Problem:


a. The boiler blowdown valve was found to be leaking.
b. Leakage was observed in the level transmitter nipple.
c. Leakage was observed in the welding of the dummy flange nipple.
d. Leakage was found in the feed water suction line.
e. Leakage found in boiler outlet valve.
f. Leakage found in main steam valve and valve in common header.
g. A droplet was observed in the water level gauge glass.
h. Gasket leakages were observed: nipple leakage on top of the boiler, in handhole and manhole.
i. Gas leakage was observed in two joints of the gas line piping.



Solution:

a. The blowdown or drain valve must be replaced.
b. Level transmitter nipple must be tightened.
c. Repair the leakage.
d. Repair the leakage of the feed water suction line.
e. Leakage must be repaired at boiler outlet val…

Top 50 Boiler Functional Problem and Solution

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 fi…

Requirements for Boiler Installation Rooms

Requirements for Boiler Installation Rooms: There are some basic requirements of a boiler room ..


1. Install a door to enter the boiler room. It may be necessary for this door to be fire rated, dependent on location of boiler room. This requirement for fire safety.

2. Proper lighting system to be provided in boiler room.







3. Proper ventilation system to be provided in boiler room.

4. Provide minimum 1 meter clearance around the boiler for maintenance. 

5. Provide proper drainage system.



Air Compressor Room Ventilation

Ventilation

The inlet grids and ventilation fan should be installed in such in way that any recirculation of cooling air to the compressor or dryer is avoided. The maximum air velocity through the grids is 5 m/s or 16.5 ft/s



Ventilation system is calculated laws is given bellow

Qv= 1.06 N/DT for Pack versions
Qv= Required ventilation capacity in m3/s
N= shaft input of compressor in KW
DT= Temperature increases in the compressor room in °C

How one design Air Compressor Pipe?

Air compressor installation Requirement

1.Install the compressor unit on a solid, level floor suitable for taking its weight 2.Position of the compressed air outlet valve.






Air compressor pressure drop calculation is given bellow DP = (L X 450 X Qc=1.85 )/ (d5 X P )
Where, D= Inner diameter of the pipe in mm DP = Pressure drop in bar, pressure drop maximum considered 0.1 bar L= length of pipe in m P= Absolute pressure at the compressor outlet in bar Qc = Free air delivery of the compressor in l/s
It must be follow the connection of the of the compressor air outlet pipe is made on top of the main air net pipe in order to minimize carry-over of possible condensate residue.


How one Operating and Testing the Air compressor Safety Valve?

How one Operating and Testing the Air compressor Safety Valve?







Operating the Air compressor Safety Valve:
Operate the safety valve by unscrewing the cap one or two turns and re-tighten it.


Testing the Air compressor Safety Valve:
Before removing the valve one must depressurize the compressor Valve can be tested and separate air line. If the valve does not open at the set pressure stamped on the valve, it must be replaced.


Caution:
No adjustments allowed Never run the compressor without safety valve Must wear goggles Must wear hand gloves

How one solves the Problem of Air Compressor?

Problem solving of Air compressor
Caution
Warning
Before start working on Air Compressor must be follow this caution
Before carrying out any maintenance, repair work or adjustment, press the stop button, wait until the compressor has stopped, press the emergency stop button and switch off the voltage. Close the air outlet valve and lock it if necessary.





Problem of Air Compressor Condition 1:
Compressor starts running but does not load after delay time.
Fault:
1.Solenoid valve out of order 2.Inlet valve stuck in closed position 3.Leak in control air flexible 4.Minimum pressure valve leaking when net is depressurized
Remedy
1.Replace solenoid valve 2.Check the valve 3.Replace leaking flexible 4.Check the valve

Problem of Air Compressor Condition 2:
Compressor does not unload, safety valve blows

How ones maintenance of Air Dryer?

Maintenance Procedure of Air dryer
Dryer Maintenance:
One must follow safety precaution any types of maintenance of dryer machine




Safety precautions:
1.Contact of Refrigerant with the skin will cause freezing. One must be worn gloves avoid this risk. If refrigerant contacted with skin, the skin should be rinsed with water. On no clothing account may clothing be removed.
2.Always should be wear safety glasses. Because fluid refrigerant will also cause freezing of the eyes.
3.Before starting work must check the area is ventilated. Because refrigerant is harmful. Do not inhale refrigerant vapours.



Dryer Machine Refrigerant:hydrofluorocarbons (HFC)

Be aware the internal elements such as the pipes can reach a temperature of 110 ?C or 230 ? F. Therefore wait until the dryer has cooled down before removing the panels.
Before starting any maintenance or repair works, switch off the voltage and close the air inlet and outlet valves.


Schedule Maintenance:
1.Must keep the dryer always clean.
2.Brush or bl…