In industrial production, industrial boilers as the core thermal energy equipment, water in which the role played by far more than a simple heat transfer medium. The continuity and stability of industrial production on the boiler's operating parameters put forward stringent requirements, which makes the industrial boiler on the quality of water, water requirements are significantly higher than civilian equipment. Pure and appropriate amount of water is not only the carrier of heat transfer, but also to maintain the safe and stable operation of the boiler foundation.
Once the water level is abnormal, will directly lead to a series of serious industrial failure. Water level is too low will lead to the boiler heating surface can not be fully cooled by the water, which led to the phenomenon of overheating, and even caused a serious pipe burst; water level is too high may affect the quality of steam, resulting in steam with water, reducing the efficiency of the use of steam. Therefore, the water level has become a boiler operation process is critical to the safety parameters, directly related to the stability and safety of the entire industrial production system.
When the water level of the industrial boiler is too low, the heated surface of the boiler cannot be effectively cooled by water, and the temperature of the pipe wall rises sharply. Prolonged exposure to such high temperatures results in fatigue of the metal material and a decrease in strength and toughness, which may eventually lead to pipe rupture. Pipe rupture not only causes boiler shutdown, but also may trigger high-temperature steam leakage, posing a serious threat to on-site personnel and equipment.
A low water level causes a significant reduction in the heat exchange efficiency of the boiler, which has to consume more fuel in order to maintain the established heating demand, leading to wasted energy and increased production costs. At the same time, the reduction of thermal efficiency will also directly affect the production capacity of industrial production, disrupting the production plan and causing unnecessary economic losses.
Feed pump as the core equipment of boiler water replenishment, once the failure, such as impeller wear, motor damage, etc., will directly lead to insufficient water supply. In addition, when the water supply capacity of the feed pump can not meet the demand of the boiler in high load operation, it will also cause the water level to fall.
The water level control device is a key component in monitoring and regulating the boiler water level in real time. Probe-type water level sensor with electrode scaling, signal transmission failure, or float-type water level control due to mechanical jamming, poor sealing, etc., will lead to inaccurate monitoring of water level, which will not be able to start the replenishment program in time, and then cause the water level to be too low.
Feed water tank as a boiler water reserve container, if its water level is too low and can not be replenished in a timely manner, or the water replenishment system due to pipeline blockage, valve failure and other reasons to interrupt the operation, will lead to the boiler can not get enough make-up water, the water level continues to fall.
Low water level alarm is one of the important safeguards for the safe operation of the boiler. If the boiler is not configured with a low water level alarm, or if the configured alarm is not maintained for a long period of time, there are problems such as sensor failure, poor contact of the alarm line, etc., the alarm cannot be issued in time when the water level is too low, and it is difficult for the operator to take timely measures to make the problem of the water level further deteriorate.
Pipes, valves, flanges and other parts of the boiler may leak due to corrosion, wear and tear during long-term operation. If the leaks are small and undetected, a large amount of water will continue to be lost over time, causing the boiler water level to continue to drop.
Operators in the setting of boiler operating parameters, if the water level control parameters are set improperly, such as low water level alarm value is set too high, which will lead to untimely replenishment of water; or misoperation in the operation process, such as wrongly closing the replenishment valve, may cause the water level to be too low.
Modern industrial boilers mostly use automation control systems, if the programming of the control system there are logical errors, such as water replenishment program does not match the boiler load, or the linkage between the automation equipment failure, will not be able to accurately control the water level, resulting in abnormal water level.
Regular inspection and real-time monitoring is an important means of timely detection of boiler water level problems. If the enterprise neglects the inspection work and fails to find the water level abnormality in time; or lacks the advanced real-time monitoring system to monitor the water level 24 hours a day, it may miss the best time to deal with the water level problem.
In order to ensure that the boiler can take timely protective measures when the water level is abnormal, it is recommended to configure two sets of main and backup Low Water Cut-Off (LWCO). The main protection device is prioritized, and when the main device fails, the standby device is automatically switched into operation, the double guarantee greatly improves the reliability of the system.
In addition to the redundant configuration of the low water level protection device, it should also establish the second redundant linkage logic of automatic furnace shutdown and automatic alarm. When the water level drops to the danger threshold, the system should not only automatically issue sound and light alarm signals to remind the operator, but also automatically trigger the furnace shutdown program to prevent further expansion of the accident.
Configuring remote monitoring and data uploading function enables the management personnel to check the boiler's water level status and operation data at anytime and anywhere through cell phones, computers and other terminal devices. Once the water level is abnormal, the system can push the alarm information in time, which is convenient for the management personnel to command and handle remotely, and it also helps to analyze the boiler operation data and discover the potential problems in advance.
By observing the pressure fluctuations of the boiler and changes in the water level meter reading, you can initially determine whether the water level is abnormal. When the water level is too low, the boiler pressure may fluctuate erratically; if the water level meter reading jumps frequently or displays anomalies, it may also indicate that there is a problem with the water level.
Compare and analyze the boiler's low water level alarm signal with the actual measured data. When the system sends out an alarm, the operator should check the actual measured data of the water level meter, pressure sensor and other equipment to confirm the accuracy of the alarm information and avoid false alarms or missed alarms.
In order to improve the accuracy and timeliness of water level monitoring, it is recommended to install a variety of types of monitoring sensors, such as magnetic flip-plate level meters, input level sensors, differential pressure level sensors and so on. These sensors can monitor the water level from different angles and transmit the data to the control system in real time, providing a reliable basis for water level judgment.
Enterprises should formulate a detailed water level inspection cycle and establish an executive record sheet according to the operating conditions and frequency of use of the boiler. Clearly specify the time, inspector, inspection content and results of each inspection to ensure that the water level inspection work is standardized and traceable.
Water level meter and water replenishment valve system in the long-term operation process, easy due to scale, impurities and other accumulation and affect the normal work. Regular cleaning and maintenance can ensure that the water level meter displays clearly and the water replenishment valve operates flexibly to ensure the normal operation of water level monitoring and water replenishment function.
Regular water supply motors, water level sensors, control modules and other key equipment to carry out a comprehensive inspection and maintenance, test its performance is normal, and timely replacement of aging, damaged parts and components to ensure that the entire water level control system is stable and reliable.
Calcium, magnesium and other ions in the water at high temperatures will form scale, attached to the heating surface of the boiler, piping and water level sensor surface. The existence of scale will not only affect the heat transfer efficiency, increase energy consumption, but also lead to clogging of make-up pipes, reducing the efficiency of water replenishment; at the same time, scale covered in the water level sensor, will make the sensor's sensing accuracy decline, resulting in inaccurate water level monitoring.
According to the water quality requirements of industrial boilers and water consumption, reasonable configuration of water treatment equipment, such as reverse osmosis devices, ion exchangers, water softening equipment. These devices can effectively remove impurities in the water, hardness ions, etc., reduce the possibility of scale generation, improve water quality, and indirectly protect the stability of the boiler water level.
Hardness, PH and conductivity are important indicators of water quality. Long-term monitoring of these parameters, to understand the water quality changes in a timely manner, to determine the operating effect of water treatment equipment. When these indicators are abnormal, the water treatment process can be adjusted in a timely manner to prevent water quality problems affecting the stability of the boiler water level and the safe operation of equipment.
Although the low water level of industrial boilers is a serious hazard, it can be effectively controlled through scientific and reasonable design, standardized and detailed maintenance and professional and systematic personnel training. Starting from the design stage of the boiler, water level risk control should be incorporated into the overall planning, and reliable water level control systems and protection devices should be configured; during the operation process, maintenance plans should be strictly implemented, and the equipment should be regularly inspected and maintained; at the same time, the training of operators should be strengthened to improve their safety awareness and operation skills, so that they can correctly judge and deal with abnormal water level conditions.
We recommend that companies customize personalized water level control system solutions based on their actual needs to reduce the risk of low water levels from the root. Personnel training, as the last line of defense to ensure the safe operation of boilers, should not be ignored. Only the design, maintenance and training of the three organic combination, the formation of a trinity of control systems, in order to truly realize the safe and stable operation of industrial boilers.
