Page 68 - Tcexpression2021 - Sept to Dec 2020

Mitigation of Boiler Accidents: Before boiler start-up, inspect the boiler and check
for the build-up of any material/ash, misaligned
Modern boilers are designed as per the established tubes, damaged burners, malfunctioning of soot
codes that make them intrinsically safe. Hence, as blowers to the extent possible
discussed earlier, boiler accidents happen mainly due to
improper operation, poor maintenance, or engineering Regularly monitor boiler parameters, identifying
judgment error. These aspects need to be strengthened any deviations and quickly address problems before
to reduce probable boiler accidents. they pose a serious threat

The following actions are suggested to assist in Check and maintain the boiler feed water quality
mitigating the boiler accidents: to eliminate/ minimise scale formation and prevent
tube failures
Proper housekeeping is essential and should never
be neglected Conduct life extension programme and periodical
residual life assessment (RLA) studies to ensure safe
Conduct regular safety audits operation of the boiler for relatively old boilers

Impart comprehensive training to operation Conclusion:
and maintenance with particular emphasis on
safety aspects. Such training should also include Recent boiler accidents on high capacity boilers
understanding boiler dynamics connected with equipped with automation controls reveal that a
off-design coal, improper operation that can lead to potential danger still exists in the form of an operational
failures, poor performance, and at times accidents. error, error of judgement or poor maintenance.
Many times, operators do not get any warning
of abnormal boiler behaviour as measurements This article broadly looks at the most common causes
of related parameters are not available. Using of such accidents and mitigation measures that can be
a predictive performance model can reveal adopted to minimise accidents.
such abnormalities in boiler operation and help
operators take corrective actions.

Tata Consulting Engineers (TCE) has developed
such a boiler performance model. A brief about the
model is given at the end of the article.

Have an effective training mechanism to revisit
the critical aspects of operation & maintenance
periodically.
Author
Strictly follow the standard operating procedures
(SOP)

Whenever in doubt regarding the boiler operation’s Lakshmana Rao - Sr. General Manager
safety, bring the boiler to a safe condition by
cutting the fuel, even if it means tripping the Tata Consulting Engineers Limited (TCE)
complete plant. This can be included in the SOP.

Ensure all the available built-in checks and safety
systems (protections, trip logics) are in place and
are not bypassed

Perform periodic calibration of critical instruments
that are connected to the safety of the boiler

68 TCExpresssion