Boiler Safety Guide |Comprehensive Boiler Safety Operation Manual

September 03, 2021

Every boiler user wants to make the boiler operate safely and stably. This not only ensures that the boiler will not be shut down for maintenance due to various problems during the operation, but also can ensure the personal and property safety of every relevant person.

Safety is no small matter. In the process of using boilers, all walks of life should practice the purpose of safety production bit by bit, and do every step of boiler safety production.

So, how can we ensure that the boiler can operate safely and stably?

1. Choose a safe and stable boiler system

2. Ensure the professionalism of boiler operators

3. Be able to quickly identify the common faults of the boiler and take the correct method to deal with it.


No matter how good the boiler is, if you don't care about maintenance, boiler failure and accidents will occur after a period of use. Through years of theoretical accumulation and on-site practice, EPCB has summarized a set of cause analysis and solutions for common boiler failures and accidents, so that everyone can learn from methods and solve problems when boiler problems occur. Ensure boiler can run efficiently and safely for a long time, thus becoming a leader in the industry.


Boiler Tube Bursting Cause Analysis and Preventive Measures


Boiler Tube Bursting Causes:

1. The boiler feed water quality is poor, no water treatment or water treatment method is incorrect, and the sewage treatment is not carried out according to relevant regulations, which causes the inner wall of the pipeline to scale or corrode;

2. Improper operation of raising fire or shutting down the furnace, causing the furnace tube to be blown by cold wind, the tube thermal expansion and contraction too fast or too frequently, resulting in harmful stress.

3. Corroded pipe burst and equipment aging burst pipe. Generally occurs in the economizer tube on the heating surface of the tail, the reason is that the exhaust gas temperature is too low or the feed water temperature is too low and the acid corrosion is caused.


Boiler Tube Bursting Preventive Measures:

1. Strengthen the management of water treatment and water quality monitoring, increase deoxygenation and iron removal equipment, change from primary softening to secondary softening, so that the boiler water can meet the standard;

2. Strengthen the management in operation, adjust the combustion, organize reasonable combustion conditions and proper flame center, and prevent cold air from blowing the furnace tube;

3. Descaling and cleaning the smoke pipe in time after stopping the furnace, and do a good job of maintenance;


If you want to learn more about the cause analysis and preventive measures of boiler tube burst accidents, please click: Boiler Tube Burst Causes and Preventive Measures


Boiler Water Level Accident Cause Analysis and Preventive Measures


Boiler Full Water Causes:

1. The boiler worker does not monitor the water level and blindly fills the water

2. The water level meter discharge cock leaks, causing the water level display in the meter to be lower than the actual water level, forming a false water level

3. The two-color water level gauge is out of order and the color display is wrong



Boiler Water Shortage Causes :

1.Boiler workers do not pay attention to work, leave their posts, and do not monitor the water level

2. Boiler workers can't judge water shortage and fullness, and blindly discharge sewage, which aggravates water shortage

3. When the boiler worker was flushing or repairing the water level gauge, he accidentally turned off the steam and water cock, resulting in a false water level



Boiler Water Level Accident Preventive measures


1. Strengthen the training and education of operating personnel, so that operating personnel can truly feel the dangers of water shortage and full water to the safe operation of the unit.

2. Strengthen business learning to understand the principles of the water supply regulation system, working performance, and the number, position and function principle of each valve to ensure the correctness of operation.

3. Strictly implement the operations specified in the regulations


If you want to learn more about the cause analysis and preventive measures of boiler water level accidents, please click: Boiler Water Level Accident Cause Analysis and Preventive Measures

Boiler Safety Accessories and Valves Common Malfunctions and Solutions


Common malfunctions of pressure gauges include the pointer not moving, the pointer does not return to the zero position, the pointer shakes, the surface is blurred, or water drops appear.

Common malfunctions of the water level gauge include leaking cock, stagnant water level, water level in the glass plate (tube) higher than the actual water level, and glass tube burst.

Common malfunctions of safety valves include air leakage, failure to open when the specified pressure value is exceeded, opening before the specified pressure value, and the valve core not returning to the seat after exhausting steam.

Common malfunctions of high and low water level alarms are that the high and low water level limit water levels do not send out alarm signals, the alarm water level does not match the actual boiler water value, and exceeds the allowable error, and one of the water levels does not alarm or alarms but does not match the actual water level of the boiler. Sometimes Normal alarm sometimes does not alarm, etc.

Common malfunctions of the blowdown device include the clogging of the blowdown pipe, the dirty discharge of the boiler, the leakage of the blowdown valve, the unscrewing of the blowdown valve, and the cracks in the blowdown valve body.


Different safety accessories and valves have different troubleshooting methods. If you want to know more details, please click: Boiler Safety Accessories and Valves Common Malfunctions and Solutions


Common Malfunctions and Solutions inside the Boiler


Common malfunctions in the boiler include: boiler overpressure accident, boiler heating surface deformation accident, furnace, flue explosion accident, tail flue secondary combustion accident, etc.


Boiler Overpressure Accidents

1.The vapor pressure rises sharply, exceeds the allowable working pressure, and the pressure gauge pointer exceeds the "red line"

2. The overpressure alarm signal is issued, and the overpressure interlock protection device is activated

3. The steam temperature increases and the steam flow decreases


Boiler Heating Surface Deformation

1. The water wall tube is deformed. If there is water shortage, the red curved water wall can be seen

2. The internal combustion furnace bladder bulges and deforms toward the fire side, and the drum bulges and deforms toward the fire side

3. The furnace tube is seriously deformed, and the sound of steam spray can be heard when the tube bursts at the same time


Furnace and Flue Explosion

1. When the furnace and flue explode, accompanied by dull noises, thick smoke and fireballs are rushed out from the explosion-proof door, furnace door, fire hole, etc., in severe cases, the furnace wall collapses and the furnace roof opens, etc.

2. When it is lighter, the explosion-proof door and furnace door are opened, there is smoke rushing out, and the chimney emits thick smoke;

Secondary Combustion in the Tail Flue

1. When the tail flue is burning, the exhaust gas temperature rises sharply, the chimney emits thick smoke, and even flames appear.

2. There is positive pressure in the furnace, and the fire is sprayed out

3. When there is an air preheater, the hot air temperature rises sharply and the wind pressure is unstable

4. The induced draft fan vibrates, the noise increases, and the current increases


If you want to learn more about the common faults in the boiler and the treatment methods, please click:

Common Malfunctions and Solutions inside the Boiler

Boiler Auxiliary Equipment Common Malfunctions and Solutions


The boiler auxiliary equipment often fails: oil-fired gas boiler burners, water pumps, fans, water supply treatment equipment, etc.


Burners Common Malfunction

1. The burner does not start

2. The burner stops immediately after starting

3. The burner is locked immediately after pre-blowing, and the flame appears


Water Pumps Common Malfunction

1. The water pump cannot start after opening the steam valve

2. There is no water after the water pump is started

3. There is a knocking sound when the pump is running



Fans Common Malfunction


1. Bearing box vibration

2. The bearing temperature rises sharply

3. Insufficient air volume and air pressure



Water Treatment Equipment Common Malfunction


1. Insufficient flow of ion exchanger

2. There is a loss of normal resin particles during the reverse selection process

3. Reduced cycle water production


If you want to learn more about the common faults and treatment methods of boiler auxiliary equipment, please click: Boiler Auxiliary Equipment Common malfunctions and Solutions


Boiler Explosion Accident Phenomenon and Preventive Measures


Fire Extinguishing in Boiler Furnace Causes:

1.The quality of coal is too poor or the coal type changes suddenly;

2.The furnace temperature is low during startup or low-load operation, or the air coefficient is too large, and the furnace has a large amount of air leakage, which reduces the furnace temperature;

3. The primary wind speed is too low or too high, the airflow direction of the four-corner DC burner is turbulent, and the powder feeder is uneven;



Boiler Furnace Explosion Accident Causes

1. Sufficient amount of combustibles and oxygen;

2.The mixture of combustible material and gas has reached the deflagration concentration;

3.Sufficient ignition energy (open flame) exists;



Measures to Prevent External Explosion Accidents in the Boiler Furnace:


1.Maintain stable combustion in the furnace and maintain a higher furnace temperature;

2.Unburned fuel shall not be discharged into the furnace of the boiler that is out of service;

3.When a fire is found, the furnace shall be purged in time to remove combustible mixtures;


If you want to learn more about boiler explosion accident phenomenon and preventive measures, please click: Boiler Explosion Accident Phenomenon and Preventive Measures




With this boiler safety operation guide, I believe you have a comprehensive understanding of all boiler safety failures, understand the boiler failures and take corresponding measures to actively prevent them, and your boiler can be used more safely and lastingly!

If you have any questions about the boiler, please contact us!


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