Boiler Maintenance Suggestions
Tips on Maintaining your Boiler –
When it comes to boiler maintenance ARE YOU PROACTIVE OR REACTIVE?
By far the worst strategy is reactive boiler maintenance. This may be defined as repairs made only when there is a failure. There is no planning, no anticipation of repairs that may be required to prevent a failure. It is only when the equipment fails that the operators will evaluate the cause and then try to make the repairs.
The costs associated with these boiler repairs are typically high both in labor, much of which is done on an overtime basis, and the associated downtime. By far this is the least desirable approach to boiler maintenance.
A proactive maintenance program pays dividends in not only peak boiler performance but also in the overall safety of those working in the boiler plant.
On the other end of the boiler maintenance spectrum is a proactive maintenance program. This type of maintenance approach uses scientific testing techniques and analysis to anticipate and correct, by either repair or replacement, problems before they arise. Real time monitoring has contributed greatly to the ability to view and respond to changes in boiler operation and overall process performance. Operators can compare past baseline results against current readings to determine if a problem may be forth coming.
The key to properly analyzing boiler room conditions is having accurate data available. Boiler room logs are an important part of this process. Critical predetermined readings, such as fuel consumption and flue gas temperatures, are recorded on a daily or even a per shift basis. These recorded readings then give the operator a base line to compare present readings against. As an example, if the flue gas temperature of a boiler has gradually increased over the course of a month the operator will be able to evaluate the system. He might then determine that there has been a build up of scale reducing heat transfer.
Keep in mind that every boiler operation is different. Some will require more extensive logs as opposed to others. This is an area that management and boiler operators must review and jointly decide upon.
Following is a suggested list of points that we feel require daily recordings:
- Water Level
- Low Water Cut Off Tested
- Blowdown Water Column
- Blowdown Boiler
- Visual check of Combustion
- Boiler Operating Pressure/Temperature
- Feedwater Pressure/Temperature
- Condensate Temperature
- Feedwater Pump Operation
- Flue Gas Temperature
- Gas Pressure
- Oil Pressure and Temperature
- General Boiler/Burner Operation
READ OVER OUR BOILER MAINTENANCE CHECK LIST!
A Check List for Planned Preventive Maintenance
P.C. McKenzie Company offers planned preventive maintenance services for a number of industrial and commercial boiler installations. Although each installation is unique there are some common maintenance steps that our service group follows.
Even though not all of these steps apply to every boiler design, we thought they might prove helpful in designing a planned preventive maintenance check list for your facility.
- Open front and rear doors. Clean and vacuum fireside surfaces as required.
- Inspect all refractory. Patch and wash coat as required.
- Inspect all gasketing on front and rear doors and replace as necessary.
- Seal and close front and rear doors properly.
- Remove low and auxiliary low water cut off controls, clean and inspect. Then re-install using new gaskets.
- Remove plugs in control piping, inspect, clean and re-install.
- Remove all hand hole and man hole plates. Flush boiler with water to remove loose scaled and sediment.
- Replace all hand hole and man hole plates with new gaskets.
- Open feedwater tank manway, inspect and clean as required. Replace manway plate with new gasket.
- Clean burner and burner pilot.
- Check pilot electrode and adjust or replace.
- Clean air damper and blower assembly.
- Clean motor starter contacts and check operation.
- Make necessary adjustments to burner for proper combustion and record all results in service report.
- Perform all flame safeguard and safety trip checks and record results in service report.
- Check all hand hole plates and man hole plates for leaks at normal operating temperatures and pressures.
- Troubleshoot any boiler system problems as requested by on-site personnel.
Our Boiler Parts Department –
With 55 + years of experience – we are the experts when it comes to finding those “hard to find” boiler parts.
We can help you with your boiler questions and put together a maintenance kit for your boiler … call toll free for or email us right here —>>> EMAIL <<<— for more info – 877-244-4883!
