Like all industrial equipment, steam boilers require periodic maintenance and inspections to ensure their correct, safe, and efficient operation.

However, boilers are machines that compromise the continuity of production in many industries. This means that shutting them down can come at a high price, not only because of the maintenance cost but also on lost production.

It is for this reason that we establish an annual maintenance plan in which we perform important inspection tasks to detect most breakdowns preemptively.

What is the maintenance plan for a steam boiler?

    • Internal inspection of the pressure body, plates, household, and tubular beam to control the formation of incrustations or corrosion of building materials.
    • Hydro-washing of sludge deposited at the bottom of the body if it exists. This is important for optimal operation.
    • Change inspection door gaskets, always install new gasket materials and check cover seats. This will avoid many accidents within the company.
    • Measurement of plate thicknesses, and cylindrical body by ultrasound, we also record these values. It may be necessary to recalculate the maximum working pressure if these thicknesses are reduced over time.

Important aspects for your steam boilers

    • Disassembly of security elements. In the case of electromagnetic level controls, check floats, bottles, verify play in mechanisms, check the integrity of the mercury ampoules and check that the insulation of the cables is not damaged.

For the electrodes, the task is cleaning parts that are in contact with water, alignment check, caulking, and seals.

    • Hydraulic test of the work pressure equipment. Performed in order to verify that there are no leaks before and after maintenance (inspection of door seals, flanges, threads, etc.). After that, the container must remain pressurized for at least 15 minutes.
    • Verification of opening of safety valves at a regulated pressure. If possible, remove them for stamping on a test bench.
    • Inspection of refractory status in a burner or dry bottoms. Fill cracks if there are any or replace damaged parts with the appropriate materials.
    • Verification of the internal state of the burner and its cleanliness. Check the condition of cables and connection cards.
    • Start-up of the equipment where the operation of the control and safety elements will be checked.
    • Gas analysis and combustion regulation. Through this process, the percentage of the following gases will be determined: O2, CO2, and CO.

Also, the temperature of the gases in the chimney, and the thermal efficiency of the boiler will be measured.

    • Preparation of a technical report with the results obtained in the measurement of combustion efficiency and the general condition of the equipment, maintaining a history.

The steps for maintaining a steam boiler are quite specific, so you should entrust it to skilled professionals. In conclusion, if you need this type of service or any other related to preventive maintenance in your facilities, let us help you.

For an industrial boiler to work at 100% performance, you must not only take into account a proper installation. But it is also essential to have a maintenance service that guarantees its performance over time. Throughout this post, we will tell you all the advantages of hiring a professional team for the maintenance of your boiler.

-Mandatory

The law establishes that annual periodic reviews must be carried out. The maintenance contract with your installation company must include all annual reports and even some repair costs. It is also necessary to perform an annual boiler cleaning.

-An efficiently run boiler saves you money

If your boiler has passed all the checks correctly, it will be at the highest possible performance. An efficient boiler means a lower power bill at the end of the month.

-An industrial boiler improves the security of your company

Hiring a maintenance service will ensure that leaks are detected on time, without exposing your company’s personnel to any risk.

Many industrial boiler maintenance companies offer a maintenance contract with emergency service with 24-hour coverage, every day of the week with professionals who will repair any breakdown in the shortest possible time to avoid delays.

-Reduce repair costs of industrial boilers

Hiring the maintenance service of your boiler with a professional company will mean savings for your company since usually, the service includes mandatory periodic reviews and some of the repair costs. If you need to carry out a preventive or urgent repair, you will probably only have to pay for the parts that need replacing.

-Warranty:

When you hire a maintenance service with a professional boiler company, the company will guarantee the effectiveness of the work. Also, the company will respond to any eventuality that occurs later. That is why it is essential to hire a professional company.

These are some of the advantages of having a maintenance service take care of your industrial boilers, so do not hesitate to ask us if you need more information.

Source: Superior Boiler

There are many types and models of heating equipment. Boilers are the most popular heating systems in the world.

Even so, it is essential to know that they require regular maintenance and inspections to ensure their correct, safe, and efficient operation.

Why is proper maintenance of the boilers necessary?

One of the most critical aspects of heating installations and, in this case specifically, of boilers, is their maintenance. Not only the boilers should be checked, but also the heating circuit. Many users think that this is an unnecessary expense until they realize how expensive it is to fix them once they break.

In order to maintain energy efficiency, it is vital to avoid emissions of undesirable gases into the atmosphere. By doing this, we also ensure the safety of our facilities and personnel. It is also worth considering that a poorly maintained boiler, in addition to increasing consumption and costs, does not generate the same amount of heat.

What are the consequences of neglecting boilers?

When boiler maintenance has not been carried out consistently, it can present a series of problems that can have a direct impact on monthly consumption. Moreover, it increases the probability of emitting dangerous gases.

Therefore, the boilers need not only preventive maintenance but a scheduled annual control, which allows us to extend the life of the system. If we avoid maintenance, problems will likely arise in the operation of the boiler, resulting in breakdowns.

The most frequent are:

If the heating system has a sudden blackout, the temperature can rise very fast, or on the contrary, the radiators could be failing to heat up. The fault may be due to a wiring problem or a sensor that blocks the recirculation pump. It is a severe problem that should be fixed as soon as possible.

Another fault that is usually more serious is the obstruction of the smoke outlet. Often, an error appears in any of the indicators that the boiler has and subsequently crashes. It is because carbon monoxide is not evacuated through the outlet duct, and, for safety, the boiler self-locks. In this case, you should contact a boiler repair service.

Sometimes it happens that the flame of the boiler does not ignite, and in this case, it is likely that the fuel suction filters are dirty. The solution is simple, but a technician must still review the heating system just in case.

Pressure drops can be very unpleasant and usually appear over time. It means that the system is not heating properly. This is an issue that you might be able to solve on your own. To get it to work correctly again, fill the circuit with the pressure recommended by the manufacturer of your boiler.

How to do preventive maintenance in boilers?

DAILY

  • Verify:
    Water level and combustion.
  • Purge:
    Background, scale, and surface:
    Pressure/temperature feed water
    Fuel gas temperature
    Fuel oil temperature and pressure
    Gas pressure
    Atomizing air pressure
    Supply and return water temperatures
    Water consumption replacement
    Vapor pressure

WEEKLY:

  • Check:

Adequate fuel valve closure
Air and fuel connections
Indicator lights and alarm
Limiting and operating controls
Security controls and connections
Filtration, noise, vibrations, abnormal conditions, etc.

SEMIANUALLY:

  • Refractory inspections
  • Check the electrical components
  • Clean:

Low water faucet
Oil pump, strainer, and filter
Air cleaner and air/oil separator
Compressor coupling alignment (fan)

ANNUALLY

  • Inspect the inside surface of the container
  • Clean:

Chimney sweeping of fire pipes

Water chamber inspection

If you follow these steps, you’ll ensure the proper functioning of your boiler. At the same time, you will achieve efficient energy consumption, which is reflected as savings in your power bills and security for your facility’s personnel.