Leaky Boiler Drum Level Switch Stops NH3 Plant Commissioning

Instrumentation engineering root cause analysis of Leaky Boiler Drum Level Switch Stops NH3 Plant Commissioning.

Article Type:Root Cause Analysis (RCA)
Equipment Type:Instruments
Author:S. Raghava Chari

Note: This root cause analysis (RCA) is from real-time scenarios that happened in industries during the tenure of two or three decades ago. These articles will help you to improve your troubleshooting skills and knowledge.

Leaky Boiler Drum Level Switch

Problem: 40-bars 250o C waste heat boiler Steam Drum Level Switch electrode packing leaks delayed an ammonia plant commissioning.

The workshop found it impossible to turn-out the flexible material-shaped packing.

The drawing has shown flexible material was unfamiliar and not available.

Leaky Boiler Drum Level Switch

Author Solution

The author got the packing done thus:

  1. Hold the electrode in the hole and wedge at the bottom with two diametrically opposite tiny wooden chips.
  2. Fill loose high temperature graphite packing around the electrode; tighten the packing nut 3 turns after filling.
  3. Insert the top ceramic sleeve to prevent electrode contacting the packing nut.
  4. Tighten the packing nut if leaks seen at full drum pressure and temperature.

Benefits Realized

The level switch electrode never leaked; thus, a very important boiler safety alarm function reliably ever.

Author: S. Raghava Chari

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