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Manufacturers design or type number Size in inches, Seat Diameter in inches( i.e the pipe size of valve inlet ) Pressure in lbs/ sq.ft or Kg / sq.cm (Steam pressure at which it is to blow) Blow down in Kgs or lbs ( BD is the difference between the opening & closing pressure ) Capacity in lbs / hr or kg / hr Capacity lift in inches. It is the distance the valve disc rises under the action of steam when the valve is blowing under a pressure of 3 % above the set pressure.
When not more than two valves of different sizes are mounted singly on the boiler, the smaller valve must not be les than 50 % in relieving capacity of the larger valve.
Every super-heater attached to a boiler with no intervening valves between the super-heater & boiler requires one or more safety valves on the super-heater outlet header.With no intervening stop valves between the super-heater & boiler, the capacity of the safety valves on the super-heater may be included in the total required for the boiler, provided the safety valve capacity in the boiler is at least 75 % of the aggregate SV capacity required for the Boiler. Ex- If a boilers steaming capacity is 100 tons, a minimum of two valves are required on Boiler with a total relieving capacity of 75 % of (100 Tons) I.e 75 tons. The super-heater would then require a SV with a capacity of (100 75) tons i.e 25 Tons.
Important Points
Heating Surface : That side of the boiler surface exposed to the products of combustion, exclusive of super-heating surface.The areas to be considered for this purpose are tubes, fire-boxes, shells, tube sheets & the projected area of the headers.
Sequence of Safety valves Blowing: The super-heater safety valves should always be set at a lower pressure than the drum safety valve ,so as to ensure steam flow through the super-heater at all times. If the drum safety valve blows first, the super-heater could be starved of cooling steam, leading to possible super-heater tube overheating & rupture.
Important Points
Re-heater Safety valves :
The capacity of re-heater safety valves can not be included in the total safety valve capacity required for the boiler & super-heater.The relieving capacity of re-heater safety valve must not be less than 15 % of the required total on the header. The total capacity on the re-heater must be at least equal to the maximum steam flow for which the reheater is designed . One SV must be on the re-heater outlet.
Installation of Safety valves: Every safety valve shall be connected so as to stand in an up-right position with spindle vertical.
contd.
CASE STUDY OF A MAJOR DISASTER IN THERMAL STATION Observations: During the investigation it was found: Explosion residue taken out from the furnace bottom was very rich in un-burnt oil and pulverized coal. Furnace wall from inside had oil sticking to the surface. Boiler operating floor was full of coal / ash/ dust and even the local BMS panel was fully covered with dust. BMS panel was never used for operating the trip valves Flame scanners were inoperative for many years and also the igniters were Non-functional. Oil used to be ignited manually by Flame Torch (Mashal ). Whenever the unit tripped the cause of tripping was never analyzed. Contd
Contd
vi)
Situation further aggravated inside the furnace since the draft fans were also not available. vii) The fuel oil supply continued to go inside the furnace since the fuel oil pumps were on station supply and the oil trip valves could not be closed manually causing boiler explosion.
vii) A systematic preventive maintenance procedure for various equipment should be evolved. viii) Procedure of Annual inspection and overhaul of boiler as per Indian Boiler Regulation should be regularly followed. ix) O&M staff should be augmented and adequate number of trained personnel should be posted for operation and maintenance.