Benefits of boiler system Maintenance

One of the most significant reasons why good boiler system maintenance is so important is because it helps prevent boiler system-related emergency shutdowns. Boilers are typically indispensable pieces of equipment at most industrial facilities. If the boiler fails then all operations at the plant can grind to a halt, stopping production and costing the plant in lost productivity. Following are the other befits of regular boiler system maintenance

Boiler Maintenance Increases the Efficiency of the Boiler

Scheduled Boiler Maintenance and Inspection Increases the Lifespan of Boiler

Regular Boiler Maintenance Helps Prevent Accidents

Certified Boiler Maintenance Saves Money

Good Boiler Maintenance is Needed for Compliance with Laws and Regulations

Boiler system maintenance Check list

Below are recommendations for daily, weekly, monthly, semi-annual and annual tasks. As always, follow your manufacturer’s recommendations for routine maintenance.

Daily Boiler system Maintenance

Blow down the bottom of the boiler system.

Blow down the water column(s) and open the drain slowly to prevent float damage.

Track boiler pressure and temperature, especially at the steady state to determine if it’s keeping up with the load.

Take a stack temperature reading to determine how efficiently the boiler is operating. A well-tuned boiler should have a stack temperature ranging between 50 – 100 degrees above the steam or water temperature.

Routinely check the gas pressure coming into the gas pressure regulator and also its downstream pressure.

For a hydronic boiler, monitor the supply and return temperatures, which are essential control variables that dictate load satisfaction based on the engineer’s design.

Look through the boiler’s sight port in the furnace and observe the flame for any evidence of impingement and possible sooting.

Observe the water softener, dealkalizer, chemical feed system and any other equipment that supports the boiler to ensure proper operation and required levels of salt and chemicals.

Take water samples on a regular basis and compare them to the recommendation.

Weekly Boiler system Maintenance

Conduct an evaporation test on the low water level control(s) to ensure proper operation and burner shutoff at the low water point.

Check the condition of the gauge glass on the low water cutoff for wear and etching.

Check the operation of the fuel supply valves.

Check the single point positioning system on the burner; if applicable, look for wear, slip and hysteresis.

Observe the operating and modulating controls, and while watching the pressure gauge, see if they are turning on and off at their respective set points.

Pull out the flame scanner to ensure the burner shuts off at the prescribed time.

Check the indicating or running lights and alarms to make sure they are functioning properly.

Assess the motors for noise and vibration.

Look for leaks of fuel, water or flue gas.

Check the high- and low-gas pressure switches and the combustion air proving switch.

Monthly Boiler system Maintenance

Check the burner’s diffuser for any deformation, burning or cracking.

Check the burner’s pilot tube that contains the electrode that provides the spark for pilot ignition.

Check the free movement of the air damper device or devices.

Check the entire outside of the boiler for signs of hot spots.

Semi-Annual Boiler system Maintenance

Remove and inspect the low water cutoff bowl and its interconnecting piping.

Pay close attention to the condition of the head assembly’s wiring and switches.

Check the pump alignment on all the base-mounted pumps in the boiler room, and reset combustion using a combustion analyzer for reading O2, CO and NOx emissions.

Annual Boiler system Maintenance

Properly shut down the boiler system and open the access doors to expose the fireside of the boiler.

Thoroughly clean the tubes and tube sheets.

Inspect the insulating materials, looking for any degradation.

Check the refractory. Cracks in the refractory insulation of 1/8” or less are okay.

On the waterside, look for heavy scaling and bridging of the tubes with scale.

Look for evidence of oxygen corrosion.

Check the gas valves and conduct the safety test recommended by the valve manufacturer.

Check the safety valve to make sure there is no sign of leakage.

On the control panel, ensure that all of the electrical connections are tight.

Inspect accessories such as the vented feedwater receiver, deaerator and chemical feed systems, if these are part of the boiler system.