During long-term operation, industrial boilers are bound to encounter some faults. Many beginners panic when faced with such issues, unsure of how to resolve them, which can lead to the problem escalating, affecting production, and damaging equipment. In fact, common boiler faults all have corresponding quick solutions. By mastering these methods, you can address issues promptly and minimize losses. Below is a summary of the five most common faults in industrial boiler operation and their solutions—beginners should save this immediately.
Fault 1: Excessive boiler pressure. Symptoms include a pressure gauge reading exceeding the rated pressure and the safety valve sounding an alarm. Solution: Immediately shut off the fuel supply and stop combustion. Open the exhaust valve or safety valve to slowly relieve pressure. Once the pressure has dropped to the normal range, investigate the cause of the high pressure (e.g., safety valve malfunction, inaccurate pressure gauge, poor circulation, etc.). After repairing the fault, restart the boiler. Note: Pressure must be relieved slowly; rapid pressure relief is strictly prohibited to avoid damaging the equipment.
Fault 2: Low Boiler Pressure. Symptoms include a pressure gauge reading below normal operating pressure and insufficient heat output. Solution: Check for leaks in the boiler (e.g., in pipes or valves); if leaks are found, repair the seals promptly. Check the thermal oil (or water) level and replenish as needed. Check whether the circulation system is functioning normally; if circulation is poor, investigate issues such as circulation pump malfunctions or pipe blockages to ensure proper circulation; if fuel combustion is incomplete, adjust the burner to ensure complete combustion and improve energy supply efficiency.
Fault 3: Incomplete fuel combustion. Symptoms include a weak, yellowish flame in the furnace, black smoke emitted from the chimney, and reduced thermal efficiency. Solution: Inspect the fuel quality; if the fuel is substandard (e.g., coal lumps are too large, biomass fuel is damp), replace it with qualified fuel immediately; adjust the air supply to the burner to ensure an appropriate air-to-fuel ratio and promote complete combustion; clean ash and oil residue from the furnace to prevent interference with flame propagation and heat transfer; check whether the flue is clear; if blocked, clear it promptly to ensure smooth exhaust of flue gases.
Fault 4: Thermal oil (or water) leakage. Symptoms include oil (or water) seeping from the boiler body or pipe joints, and a rapid drop in liquid level. Solution: Immediately shut down the boiler, reduce temperature and pressure, and close the valves upstream and downstream of the leak to isolate the leak point; Investigate the cause of the leak; if caused by damaged seals, replace them promptly; if caused by damage to pipes or the boiler body, repair or replace the components immediately; after repairs, replenish the heat transfer oil (or water), conduct a pressure test, and ensure there are no leaks before restarting the boiler.
Fault 5: Circulation pump fails to start. Symptoms include the circulation pump not running after power is applied, or stopping immediately after starting. Solution: First, inspect the power supply and electrical circuit to resolve issues such as short circuits or poor connections; check the circulation pump’s motor and bearings—if the motor is damaged, repair or replace it promptly; if the bearings are low on oil, replenish the lubricant; check the thermal oil (or water) level—if it is too low, top it up before restarting; check whether the circulation pump’s impeller is jammed—if so, clear any debris from the impeller to ensure it rotates normally.
Note for Beginners: In the event of a malfunction, first shut down the boiler and ensure safety precautions are in place before troubleshooting. Never force the boiler to start before the fault has been resolved. If you encounter a fault that cannot be resolved, contact professional maintenance personnel immediately to avoid unauthorized operation that could lead to safety incidents. Regular maintenance of the boiler can effectively reduce the occurrence of malfunctions.
