Boiler Accidents Part II for education.ppt

Boiler Education

1. Presented by : -
Sanjay M. Sarode
B.E(Mech.), A.M.I.E(Elect), D.B.M, D.L.L, D.I.T
Dy. Director, Steam Boilers, M.S.
Part -II

2. Let us have a look at
-Some of the accidents
occurred to boilers &
economisers.
-Some defects commonly
observed.

3. BOILER MR/10985
Ordnance Factory
Varangaon,
Jalgaon
Nature of accident
Multiple bulges in
furnace
Cause of accident
Low water level

4. BOILER MR/9616
Govt. Milk
Scheme, Miraj
Nature of accident
Bulging of furnace
Cause of accident
Low water level

5. BOILER MR/9616
Govt.Milk scheme,
Miraj
Nature of accident
Furnace collapsed
–internal view
Cause of accident
Low water level

6. BOILER MR/9198
Jasmine Mills Pvt.
Ltd, Dharavi
Nature of accident
Multiple bulges in
furnace with cracks
Cause of accident
Low water level

7. BOILER MR/11581
Thermax Ltd,
Pune
Nature of accident
Corrugated
furnace collapsed.
Boiler tubes
pulled out from
tube plate.
Cause of accident
Low water level

8. BOILER MP/217
Gopal Rice Mills,
Gondia
Nature of accident
Bulging of furnace
Cause of accident
Low water level

9. BOILER MP/217
Gopal Rice Mills,
Gondia
Nature of accident
Picture shows
Damaged
foundation &
damage to the
property
Cause of accident
Low water level

10. BOILER MP/217
Gopal Rice Mills, Gondia
Nature of accident
The vertical X tube boiler
thrown away from
foundation at about 5m.
distance causing
damage the property &
loss of one life.
Cause of accident
Low water level

11. BOILER MR/10750
Jaysynth Dyechem
Ltd, Navi Mumbai
Nature of accident
Bulging of furnace
Cause of accident
Low water level

12. BOILER MR/10750
Jaysynth Dyechem
Ltd, Navi Mumbai
Nature of accident
Furnace teared off
from F.E.P.
Cause of accident
Low water level

13. Trimbak Rubber,
Nashik
Nature of accident
Bulges to furnace
Cause of accident
Low water level

14. Trimbak Rubber,
Nashik
Nature of accident
Bulges to furnace –
seen internally
Cause of accident
Low water level

15. BOILER MR/9623
RajaramBapu S.S.K.
Ltd., Walva, Sangli
Nature of accident
Few holes of boiler
tubes were plugged
Cause of accident
Low water level

16. BOILER MR/9623
RajaramBapu
S.S.K. Ltd., Walva,
Sangli
Nature of accident
Water tubes got
pulled out from the
drum
Cause of accident
Low Water Level

17. BOILER MR/9623
RajaramBapu S.S.K.
Ltd., Walva, Sangli
Nature of accident
The Roof is
distorted and super
heater coils collapsed
Cause of accident
Low water level

18. BOILER MR/9623
RajaramBapu
S.S.K. Ltd., Walva,
Sangli
Nature of accident
Several tubes of
boiler were twisted
Cause of accident
Low water level

19. BOILER MR/11801
M/s. Viva Herba Pvt Ltd,
Panvel
Nature of accident
Bulge to the furnace
Cause of accident
Low Water Level

20. BOILER MR/11801
•M/s. Viva Herba Pvt
Ltd, Panvel
•Nature of accident
Bulge to the furnace
Exploded view
•Cause of accident
Low Water Level

21. BOILER MR/12463
M/s. Vinyl Chemicals (I)
Ltd, Mahad
Nature of accident
Furnace collapsed
Cause of accident
Low Water Level

22. BOILER MR/12463
M/s. Vinyl Chemicals (I)
Ltd, Mahad
Nature of accident
Furnace collapsed
Cause of accident
Low Water Level

23. BOILER MR/11874
M/s. Spec Chemicals Ltd
Nature of accident
Bulge to furnace
Cause of accident
Low Water Level

24. BOILER MR/11537
Daga Plastic
Industry, Jalgaon
Water gauge glass
bottom header
partially choked
Cause: -Poor
water quality

25. BOILER MR/11537
Daga Plastic
Industry, Jalgaon
Mobery duel
control bottom
stand pipe branch
in the boiler shell
choked with
sludge
Cause:-Poor
water quality

26. BOILER MR/11537
Daga Plastic
Industry, Jalgaon
Mobery dual
control stand pipe
bottom branch
choked with
sludge
Cause:-Poor
water quality

27. BOILER MR/12910
Unique Sugars,
Dondaicha
Nature of accident
Puncture of bed
coil
Cause of accident
Erosion of bed
coil

28. BOILER MR/12910
Unique Sugars,
Dondaicha
Nature of accident
Puncture of Bed
coil due to erosion
Cause of accident
Erosion of bed
coil

29. BOILER MR/12910
•Unique Sugars,
Dondaicha
•Nature of accident
Puncture of Bed
coils
Cause of accident
Erosion of bed coil

30. MALEGAON SIZING
Corrosion and
wasting of
smoke tubes

31. BOILER MR/13241
M/s. Sagar Distillary
Nature of accident
Side wall tubes of
Furnace
Overheated –Bulged -
Increased in dia.
Cause of accident
Poor water quality

32. BOILER MR/13241
Sagar Distillary
Nature of accident
Super heater coil
plugged due to heavy
scale formation
Cause of accident
Poor water quality

33. BOILER MR/11874
Fully Choked bottom
S/P of Boiler

34. BOILER MR/13272
M/s. Govardhan
Petrochemicals,
Nandurbar
Nature of accident
Badly overheated
smoke tube.
Cause of accident
Scale

35. M/s. Niphad S.S.K.
Ltd.,
Nature of accident
Over heating &
bulging of w/w tube.
Cause of accident
Low water level

36. BOILER MR/13391
M/s. The Raver
Shetkari. S.S.K.
Ltd., Omkareshwar,
Dist.: Jalgaon.
Nature of accident
The fish mouth type
opening of w/w tube
due to overheating
Cause of accident:
Low water Level

37. BOILER MR/9237,MR/9238
M/s. M.S.E.B.
Deepnagar,
Nature of accident
Puncture of
Economiser Coils
Cause of accident
Erosion of eco. coils

38. BOILER MR/9376, MR/12702
M/s. Rawalgaon Sugar
Farms
M/s. Pushpadanteshwar
S.S.K. Ltd., Samsherpur
Nature of accident
Puncture to economiser
coils
Cause of accident
Corrosion / wasting

39. M/S Shalimar
Sizing, Malegaon
Nature of accident
Tube Leakage
Cause of accident
Badly Scaled
Smoke Tubes
BOILER M/2973

40. BOILER MR/13067
M/s. Bhagwati Refineries
Pvt Ltd. Pachora, Jalgaon
Nature of accident
Bulging of Ext. W/W
Header
Cause of accident
Internal Scale

41. BOILER MR/13067
•M/s. Bhagwati Refineries
Pvt Ltd. Pachora, Jalgaon
•Nature of accident
Bulging of Ext. W/W
Header
•Cause of accident
Internal Scale

42. BOILER MR/12740
M/s. Jain Irrigation
Systems Ltd
Nature of accident
Damage to shell
Cause of accident
Improper Handling

43. BOILER MR/12740
M/s. Jain Irrigation
Systems Ltd
Nature of accident
Damage to shell upto
50mm depth
Cause of accident
Improper Handling

44. BOILER MR/12740
M/s. Jain Irrigation
Systems Ltd
Nature of accident
Damage to stand pipes
Cause of accident
Improper Handling

45. BOILER MR/9594 & MR/9595
M/s. Nashik Thermal
Power Station
Nature of accident
HRH Lig. Crack
Leakage
Cause of accident
High Tempt Creep

46. BOILER MR/9594
M/s. Nashik Thermal
Power Station
Nature of accident
Crack to Conv. SH O/L
Header
Cause of accident
High Tempt Creep

47. BOILER MR/9595
M/s. Nashik Thermal
power Station
Nature of accident
Leakage of coils –PSH-
R4
Cause of accident
Long Term Overheating &
Weld Joint Defect

48. BOILER MR/9595
M/s. Nashik Thermal
Power Station
Nature of accident
Tube Leakage-PSH R4
Cause of accident
Thinning due to flue gas
erosion

49. BOILER MR/10299
M/s. Nashik Thermal
Power Station
Nature of accident
Tube Leakage-Eco
Cause of accident
Bottom-Thinning due to
flue gas erosion
Top-Secondary Damage

50. BOILER MR/10299
M/s. Nashik Thermal
Power Station
Nature of accident
Tube Leakage-W/W
Burst
Cause of accident
Hydrogen Embrittlement

51. BOILER MR/10299
M/s. Nashik Thermal
Power Station
Nature of accident
Tube Leakage-W/W
Burst-Fish Mouth
Opening
Cause of accident
Thinning due to Steam
Erosion from soot
blowing

52. BOILER MR/10299
M/s. Nashik Thermal
Power Station
Nature of accident
Tube Leakage-LTSH
Cause of accident
Porosity in weld joint
during erecton

53. BOILER MR/10299
M/s. Nashik Thermal
Power Station
Nature of accident
Tube Leakage-LTSH
Cause of accident
Secondary Damage

54. BOILER MR/10299
M/s. Nashik Thermal
Power Station
Nature of accident
Tube Leakage-LTSH
Cause of accident
Thinning due to flue gas
erosion & bursting during
HT

55. BOILER MR/10299
M/s. Nashik Thermal
Power Station
Nature of accident
Tube Leakage-HRH
tube
Cause of accident
Long Term Overheting

56. BOILER MR/10299
M/s. Nashik Thermal
Power Station
Nature of accident
Tube Leakage-HRH
tubes
Cause of accident
Secondary Damage to
HRH tubes

57. BOILER MR/10433
M/s. Nashik Thermal
Power Station
Nature of accident
Tube Leakage -LTSH
Cause of accident
Top-Weld joint porosity
Middle & Third-Secondary
Failure

58. BOILER MR/10433
M/s. Nashik Thermal
Power Station
Nature of accident
Tube Leakage-W/W
Cause of accident
Thinning due to Soot
Blower Steam Erosion

59. BOILER MR/10553
M/s. Nashik Thermal
Power Station
Nature of accident
Tube Leakage-RH
Cause of accident
Dissimilar Metal Weld
Joint Failure

60. BOILER 10553
M/s. Nashik Thermal
Power Station.
Nature of accident
Tube Leakage-RH
Cause of accident
Secondary Damage to
RH Coils

61. BOILER MR/10553
•M/s. Nashik Thermal
Power Station.
•Nature of accident
Tube Leakage-RH
•Cause of accident
Dissimilar Metal Weld
Joint Failure

62. BOILER MR/10553
M/s. Nashik Thermal
Power Station.
Nature of accident
Tube Leakage-RH
Cause of accident
Secondary Damage to
RH Coils

63. BOILER MR/9595
M/s. Nashik Thermal
Power Station.
Nature of accident
Tube Leakage –W/W
Cause of accident
Attachment Failure/
Stress Rupture

64. Concept & Design by
Sanjay M. Sarode,
Dy. Director, Steam Boilers,
Maharashtra State.