RETURN

ME101
Expulsion from the Safety Valve of D rum Due to Blockage of the
No.2 Boiler Superheater Needle Valve
Technical committee

Expulsion from the safety valve of drum due to blockage of the #2 boiler superheater needle valve
(Boiler MDM-901)

1. Outline of breakdown
After entering dock at Malaysias MSE and completing Docking work, the ship once again set sail in order
to carry out sea trials.
While carrying out ballasting (operation of 2 cargo pumps) and after repeatedly increasing and
decreasing the main engine speed for about 2.5 hours, the main engine speed was set to 50 rpm. At this
time, the boiler was operated with AS-22 x 3 units at oil pressure 17kg/cm. By an order from the
bridge, the speed was increased to 55 rpm. Due to a rise of boiler load, the #4 burner ignited. Immediately
afterward, the oil pressure increased to 20kg/cm, the #2 boiler drum pressure rapidly increased, and
finally resulted in expulsion from the safety valve of drum.
The main engine speed was immediately reduced and anchor was let go at Johol Anchorage for
safety reasons.
The following day, with assistance from the dock workers, various inspections were carried out to
ascertain the cause of this breakdown. As blockage of the #2 boiler superheater needle valve was assumed,
this boiler was stopped and overhaul inspection of the needle valve was carried out. Investigation revealed
that the superheater hand hole plug was caught which caused blockage.

2. Causes
The hand hole plug which was left inside the superheater header was pushed toward the needle valve due
to the flow of steam during operation. This caused blockage of the valve.

3. Countermeasures
Recently, as the docking period is short, especially with regard to turbine vessels, the later half of the
docking period becomes very busy and there always seem to be a shortage of workers. Moreover, at
overseas docking yard, worker carry out which exceeds what we would consider to be reasonable behavior
seems to take place without second thought. As work continues late into the night, sufficient wariness is
required. Therefore, when docking at overseas, it is important to formulate a plan of action when trading
spare parts for supplies.

1
The Marine Engineer Jan.1989