The presentation includes technical problems and their troubleshooting while handling boilers in industry.

2. Group No. 07
PRESENTED TO
Muhammad Sajid Liaqat 14083123-022
Faran Hassan 14083123-023
Zeshan Abbas 14083123-028

3. TROUBLESHOOT
PROBLEMS

4.  Boiler Produces No Heat
 Poor Heating Performance
 Water Leakage Around Boiler
 Not All Radiators Heat
 Noisy Pipes
 Boiler Turns Off
 Noisy Boiler or Noisy Central Heating
 Thermostat Doesn’t Work Correctly
 Boiler is Losing
 Low Water Conditions Pressure

5.  Possible Causes
1) Boiler has no power
2) Water level is low
3) Pilot or electronic burner
ignition malfunction
4) Thermostat malfunction

6.  Circuit breaker or fuse controlling the furnace is tripped
or blown. Reset tripped circuit breaker. Replace blown
fuse.
 Maintain water level at half full. The boiler's automatic
filling system using the pressure relief valve should
maintain proper water level by maintaining a 12-15 psi
pressure. If you do not have a pressure reducing valve
you can also manually feed the boiler by the water feed
valve until boiler pressure reaches 12 psi.

7.  Possible Causes
1) Sudden Change: Improper
water level
2) Gradual Change: Mineral
deposits in boiler and heat
exchanger

8.  Check reading of the Tridicator (combination pressure /
temperature gage). If water pressure is low (below 12
psi) the system needs to have water added. The boiler's
automatic filling system using the pressure relief valve
should maintain proper water level by maintaining a
12-15 psi pressure. If you do not have a pressure
reducing valve you can also manually feed the boiler
by opening up the water feed valve until boiler pressure
reaches 12 psi.

9.  Possible Causes
1) Faulty circulator (pump)
2) Faulty pressure relief valve
3) Leaking water pipe
connection

10.  Most repairs to the circulator will require a service
technician.
 If the circulator is leaking replace the pump seal.
 If the pressure relief valve is leaking, the system
expansion tank may be filled with water.

11.  Possible Causes
1) Trapped air in line
2) Trapped air in radiator (top is cooler
than bottom)
3) Faulty zone valve or circulator

12.  Bleed air from cool radiator by opening radiator bleed
valve at top of radiator. When water squirts from
radiator, close valve.
 Check circulator for proper operation (motor runs).
There may be dedicated circulators for different heating
zones in the home.

13.  Cause:
This can happen for a number of
different reasons, including low
water pressure, thermostat issues, or
if you have a frozen condensate pipe,
air in the system or a faulty pump.

14.  What to do:
If it is cold outside, you may need to thaw your
condensate pipe. You can also try bleeding your
radiators to remove any air in the system. If you notice
that your water pressure is low, you can fix it by
adjusting pressure.

15.  Cause:
A noisy boiler is often caused
by “Kettling”, which is a build
up of lime scale in the heat
exchanger.Whistling pipes can
be caused by a build up of lime
scale or air in the system.

16.  What to do:
By bleeding your radiator or power flushing your pipes,
you can remove lime scale and air from your system

17.  Cause:
This could be caused by a
faulty thermostat. Older
thermostats tend to deteriorate
over time, and can cause issues
for your central heating
system.

18.  Cause:
There are a number of reasons
why this may happen, from
loose connections inside the
boiler, to broken parts.

19.  Cause:
If you have a pressurized
system, you may notice that it
keeps losing pressure. This
could be caused by a water
leak, or a problem with the
expansion vessel.

20.  Possible Causes
1) Faulty circulator
2) Water trapped in return lines
Adjust pitch of radiator with a shim so
that it slopes back toward the return pipe.

21.  Check the circulator. There is a spring loaded coupling
that connects the pump to the motor. When it breaks
after the pump jams, the coupling will make a loud
noise as the motor runs.
 Check that the pitch of the return lines slope back
toward the boiler. Adjust pitch with new pipe hangers if
necessary.

22.  A low water condition in a steam boiler is any situation
in which the water dips below the minimum safe
operating level as intended by the manufacturer. If the
situation continues without replacing the water, the
metal, normally cooled by boiling water, must now be
cooled by steam. Since heat transfer to steam is not as
rapid as to boiling water, the metal gets hotter. When
the metal gets too hot, it loses its mechanical strength
and fails.

24.  Boiler explosion at Samut Prakan cloth dyeing
factory factory injures 21
2008, THAILAND

25. Police suspect that the boiler exploded because there
was not enough water in it. The cost of
the damage is estimated to be over one million baht.
Prajak Makaew, a 38-year-old factory worker, said he
heard a loud explosion while working on a night shift
inside the factory building.

26.  Ghakhar Mandi,Gujranwala Pakistan.
 In 2015.
In feed making industry.
 Boiler exploded and 7 people died.
 Boiler exploded due to high pressure and corrosive
conditions.