Many of us have experienced the impact of a boiler system failure. OSHA references four major categories of catastrophic failure which exist in the boiler itself.
- Melt down. This is a result of the heating surface metal reaching its melting point. It is a result of the boiler operating on very low water conditions. This by itself will not cause an explosion but will do major damage to the boiler and create a dangerous situation which could lead to an explosion.
- Thermal Shock. This is a condition where low water causes the heating surfaces to become overheated and then cooler water is added. The water then flashes to steam which expands 1600 times its volume as water and causes the explosion because there is not enough room for the steam to expand.
- Combustion explosions. These can be a result of gases which build up and an ignition source ignites the gases. This can happen inside the boiler or outside. There are safety devices that should be in place to avoid these.
- Steam Pressure. Excessive steam build up which exceeds the design pressures of the vessel. There are also safety devices to prevent this.
Preventing Failures and Saving Money
Trap Energy Solutions owner, Garrett Trapnell, witnessed these failures – or near failures – first hand when he served as a boiler inspector. He acquired his Chief A boiler operator license and later earned a National Board commission as a boiler & pressure vessel inspector, where he worked for nearly 20 years. “I was shocked by the neglect I saw with some systems, knowing how dangerous poorly maintained boilers can be,” Trapnell said. “In addition, these companies were losing money because of how inefficiently their boiler systems were operating.” That’s when he decided that it was time to start helping people protect their employees and their bottom lines by finding energy saving solutions and mitigating exposures with good risk control measures.
Trapnell uses a 20-point comprehensive steam boiler evaluation that provides an internal inspection is conducted during annual shutdown periods. Evaluation results are analyzed and summarized in a detailed and graded report, which is submitted within 3 days of the evaluation. He recommends that a comprehensive boiler inspection is conducted every three years.
The boiler evaluation includes:
- Thorough Internal Surfaces Inspection
- Borescope Visual Inspection: Water Tubes
- Scale Deposit Evaluation
- Controls and Safety Devices Audit
- Jurisdictional Compliance Audit
- Pressure Gage Check
- Low-Water Fuel Cutoff (LWCO) Assessment
- Refractory Visual Inspection
- Steam Valves Visual Inspection
- Boiler End-of-Life Assessment
- Ultrasonic Thickness (UT) Survey: Tubesheet, Furnace Tube
- Liquid Penetrant (PT) Weld Inspection: Furnace Tube
- Pressure Relief Safety Valve Visual Inspection
- Boiler Doors and Gaskets Check
- Water Treatment Records Review
- Maintenance Records Review
- Repair History Audit
- Foundation Assessment
- Boiler Insulation Evaluation
- Boiler Shell Condition
Optional follow-up visits offer additional insights:
- Complete CSD-1 Operational Checks
- LWCO Evaporation Checks
- Combustion Analysis
- Boiler Efficiency Calculations
- Carbon Emissions Calculation
- Infrared (IR) Thermal Imaging
Important Additional Services to Increase Boiler System Safety & Efficiency
Trap Energy Solutions provides the following services that are important to maintaining optimal safety and efficiency in a boiler system.
The U.S. Department of Energy in Steam Tip Sheet #1, warns that “In steam systems that have not been maintained for 3 to 5 years, between 15% to 30% of the installed steam traps may have failed—thus allowing live steam to escape into the condensate return system.” The Steam Trap testing intervals recommended by the U.S. Department of Energy are:
- High-Pressure (150 psig and above): Weekly to Monthly
- Medium-Pressure (30 to 150 psig): Monthly to Quarterly
- Low-Pressure (below 30 psig): Annually
We go into more detail about our Steam Trap Survey process in an earlier post: Ignoring Steam Traps Causes Significant Losses.
Descaling Services for Boilers, Water Heaters, and Other Equipment
Equipment Performance is improved when scales and deposits are removed. Descaling increases the efficiency and performance of boilers, water heaters, and other equipment. This translates into energy savings, reduced maintenance costs, and extended equipment life. We provide information about our process in an last month’s post: Trap Energy Solutions Announces Descaling Services for Boilers, Water Heaters, and Other Equipment
Contact Trap Energy Solutions to learn more about how Boiler Inspections, Steam Trap Surveys and Descaling provide a safer work environment and increase the efficiency of your boiler system – reducing risk and helping your company save money.
Contact:
Garrett Trapnell (Owner - Trap Energy Solutions)
P: (612) 865-5366 E: garrett@trap.energy