Problem with Boiler Pipes

Hi Miodrag, While I have no immediate experience with boilers, some of the basic laws of Pressure, Temperature and Volume come to mind. It sounds like you have too much pressure in system generally, perhaps from elevated temperatures. Have you checked your thermostats, pressure & temperature regulators and instrumentation for accuracy? Perhaps some additional localized (temporary) sensors to ascertain for certain your operating conditions at various stages of the system will shed some light on your troubles. Good luck with this, DougRH

How are you pretreating your boiler water. What Ph are you running what are the dissovled soilds what preasures are you running.

Are you getting water/steam hammer in your pipes.Ive got many questions. Has the pressure exceeded the schedule of the piping?Was the piping thermal shocked by to quick of a start-up.If I can help let me know.

1.check operating pressures and temperatures 2. check feedwater and boiler water dosing especiallly total dissolved solids. 3.is boiler warmed up too quickly? are you using the corrct boiler for your application, should you have a thermal storage control system?

Check your condensate return system, as this sounds like a severe case of water hammer. If that checks out, you have one or more safety and/or operating malfunctions. To create leaks at the risers AND explode pipes is pretty rare these days. If your pipes aren't exploding from water hammer, which you will hear, and feel, then you have way too much pressure being created from the superheaters, as you are describing piping problems downstream of your last pressure vessel. If nothing makes sense, replace the main line traps, and for safety sake, install some kind of blowdown so that you may drain any accumulated condensate. Why isn't your high pressure cut out opening, and why aren't your relief valve(s) opening to reduce your extreme pressures? WATER HAMMER !!!