Importance of Boiler Safety Management Systems

Boiler Safety is of utmost importance. Boilers are an indispensable part of steam systems. Boilers are pressure vessels and hence, safe boiler operation is must for overall safety of the workplace. Over the period, as technology has evolved, boiler safety can be maintained in a much better way compared to the past. Boiler safety management systems can tremendously enhance the safety of boilers and personnel working nearby.

After analysing 100 boilers for a week for various safety breaches, following graph was obtained.

As it can be observed, most of the safety issues are linked closely with the boiler operation. Manual operation of boilers generally leads to overlooking some of the safety conditions and this might result in a safety hazard.

 Equipping the boiler with an automatic safety management system can avoid occurrence of such human error and take boiler safety to an altogether different level. Before we take a look at how boiler safety monitoring systems work, it will be useful if we go through all the safety breaches, study the reasons they arise and suggested corrective actions to be taken.

As it can be seen from the table above,a good boiler safety monitoring system will continuously monitor and generate trends and diagnostics and alarms in case of any breaches for following paramters-  

  •  Flue gas oxygen (%)
  •  Flue gas carbon dioxide (%)
  •  Excess air (%)
  •  Oil pressure (Bar g)
  •  Boiler drum level (%)
  •  Oil temperature (°C)
  •  Flue gas temperature (°C)
  •  Combustion air temperature (°C)
  •  Furnace pressure (mmWC)
  •  Day oil tank level (%)
  •  Feed water level (%)
  •  Blowdown TDS (ppm)

 Intelligent alarms and diagnostics:

  •  High flue gas O2 / CO2 %
  •  Low flue gas O2 / CO2 %
  •  Low Oil pressure
  •  High Oil pressure
  •  Drum level low
  •  Drum level too low
  •  Very High furnace pressure
  •  Very negative furnace pressure
  •  Replace oil nozzles
  •  Low Oil temperature
  •  High Oil temperature
  •  Low Flue gas temperature
  •  High Flue gas temperature
  •  High Drum TDS
  •  Possibility of backfire
  •  Feedwater tank level low
  •  Feedwater tank level too low