What can cause overheating and failure of boiler tubes?

Burner flame impingement is considered a significant cause of overheating and subsequent failure of boiler tubes. This phenomenon occurs when the flames from the burner come into direct contact with the metal surfaces of the boiler tubes. Normally, boiler tubes are designed to be cooled by the water or steam circulating around them, which absorbs heat and maintains appropriate temperature levels. However, if the flames are directed improperly due to issues such as misalignment or malfunctioning burner components, the tubes can experience an excessive temperature rise.

When the temperature of the boiler tubes exceeds the material's allowable limits, it can result in the weakening and eventual failure of the tubes, often manifesting as burns, cracks, or ruptures. Such failures not only lead to costly repairs but also create potential safety hazards, including the risk of explosions or steam releases. Preventative measures, such as ensuring proper burner alignment and regular maintenance, are essential to mitigate the risk of flame impingement and protect the integrity of the boiler system.