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Boiler tube leakage is one of the most common problems in industrial boiler operation. If not handled promptly, it can easily lead to boiler shutdown, reduced energy efficiency, and even safety accidents. This article will systematically introduce the causes, symptoms, and repair procedure and methods for boiler tube leakage to help you quickly address boiler tube leakage issues.
After the boiler has been used for a long time, the pipelines will age due to corrosion, wear and other reasons, which will cause pipeline leakage.
The boiler temperature is too high, which will also cause the pipeline to loosen and age, resulting in leakage.
Poor installation, untightened and loose pipeline connections, etc. may also cause leakage.
Pipe extrusion or deformation will also cause cracks in the pipeline and leak.
The boiler water temperature is too high, which is also one of the reasons for boiler tube leakage. Excessive water temperature will increase the pressure on the pipeline and cause the pipeline to crack.
During boiler operation, closely monitoring
the following abnormal phenomena is crucial for timely detection of boiler tube
leaks:
The feedwater flow rate is abnormally
higher than the steam flow rate, and a stable water level cannot be maintained.
The flue gas temperature near the leak
point will decrease. Simultaneously, the steam temperature at the outlet of the
superheater or reheater on the corresponding side may show abnormal increases
or decreases.
A sudden increase or drastic change in
furnace negative pressure may be accompanied by a significant increase in
induced draft fan current.
A distinct steam jetting sound can be heard
near the leak point.
The flue gas detector shows increased flue
gas humidity; simultaneously, the carbon content of fly ash may also increase.
White steam emerges from the inspection
port, manhole, etc. In severe cases, water may drip from the tail flue, and the
exhaust gas temperature continues to drop.
It is important to note that any single
abnormal symptom may not be conclusive evidence, but when multiple of the
above-mentioned symptoms appear simultaneously, it can generally be determined
that the boiler tubes are leaking.
The boiler tube repair procedure is:
Upon discovering a leak, immediately shut
down the boiler and cut off the fuel supply to prevent further leaks and
accidents.
Close the water supply valve to stop
supplying water to the boiler and reduce the leaking pressure.
Open the vent valve on the leaking pipe to
release the pressure inside the boiler and reduce the leaking pressure.
Inspect the leaking area for severe damage
or wear. If necessary, replace or repair the fittings at the leaking point.
If the leak is caused by a loose pipe
connection or poor sealing, use an appropriate sealant or lubricant to reseal
it.
After repairing the leak, perform a
pressure test to ensure that the boiler tubes are completely repaired and no
longer leaking.
After confirming that the boiler tubes have
been repaired and there are no leaks, the water supply valve can be reopened to
restore water supply and the boiler can be restarted.
1. In extreme emergencies, it is necessary to stop the furnace immediately for treatment, and close the water valve and gas valve in time to avoid further leakage accidents.
2. Find the location of the leak: The leak can be found based on the sound of the leak, the bubbling of the pipeline and the connector, so as to better repair it.
3. Use soil or cement to plug the leak: For small leaks, you can use soil or cement to plug the leak and cover it with dry soil to reduce the extent of the leak.
If the leak is serious, it is recommended to replace the leakage tube directly. This method is more thorough and can eradicate the leak problem, but the cost is relatively high.
Chemical lap treatment is a relatively simple method, which is suitable for situations where the pipeline leak is relatively small. Use chemical lap materials to fill the leaks in the pipeline so that the leaks do not continue to expand.
Welding treatment is a relatively effective method, but you need to pay attention to some details and risks. First, you need to choose the appropriate welding materials and methods. Secondly, you need to pay attention to the temperature and environment around the pipeline to prevent safety accidents such as fire during welding. In addition, when performing welding treatment, you need to follow the specifications and conduct necessary inspections and tests to ensure that the welded pipeline can work normally.
When welding boiler tubes, you need to pay attention to the following aspects:
Before welding, you need to clean up the debris around the pipes to ensure that there are no impurities affecting the welding effect during welding.
Choosing the right welding materials and methods can ensure the welding effect. Generally, MIG gas shielded welding or TIG argon arc welding is selected for boiler pipe welding.
When welding, the area around the pipe needs to be protected from damage. You can use materials such as fire blankets to cover the area around the pipe.
After welding, the weld needs to be inspected and tested to ensure that there are no cracks and water leakage at the weld of the pipe.
When welding boiler pipes, you need to pay attention to safety and skills. If the technology and conditions do not allow, it is recommended to choose other appropriate treatment methods.
For aging pipelines, new pipelines need to be replaced to avoid further leakage.
For problems such as poor installation, untightened or loose pipe connections, thorough inspection and improvement are required to ensure the normal operation of the pipes.
Strengthen daily inspection and maintenance work, timely discover and deal with boiler problems, and avoid escalation of problems.
1. Don't be impatient when dealing with boiler tube leaks. Analyze calmly and take corresponding countermeasures.
2. Strictly abide by safety operating procedures to ensure the safety of personnel and equipment.
3. If you cannot judge or deal with the boiler tube leaks problem, you should contact professional technicians in time for treatment.
In short, for the boiler tube leakage problem, we must deal with it in time and take corresponding measures to solve it, avoid further expansion of the leakage problem, and ensure the safety of personnel and equipment.
In general, boiler tube leakage is not an isolated problem, but rather the result of a combination of long-term operation, improper maintenance, or abnormal operating conditions. When a leak occurs, the cause should be carefully analyzed, and appropriate repair methods should be adopted. If necessary, the boiler tube should be replaced or repaired by professionals to ensure the long-term, safe, and efficient operation of the boiler equipment.
Read more: Boiler Tube Failure Causes and Reduction or Causes and Preventive Measures for Boiler Four-tube Leakage
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