Boilers are highly productive for industries, but if they’re not accurately inspected and maintained, they can become fatal too. According to a report, there are countless breakdowns, innumerable accidents, and unnecessary boiler shutdowns faced by industrial boiler manufacturers in India. Most of these boilers are operating in the food processing, chemical, refining, paper, and primary metals industries.

Here are a few basic and best practices for maintaining the desired efficiency of the boiler:

Keeping the Boiler Clean

Boilers require following a critical cleaning process, as any residue (such as scale or soot) that may get attached, or coat over the heat transfer surfaces of the boiler. These depositions may reduce the efficiency of the boiler and also double the chances of equipment failure. The residue that coats over the tubes of a boiler may elevate the flue gas temperature and interfere with heat transfer. Improper maintenance can also result in incomplete combustion, resulting in the accumulation of soot on the combustion side of the tubes. Likewise, poor water treatment practices can also result in scale accumulation on the waterside of the pipes.

However, following the manufacturer’s recommendations and cleaning the surface as per the plan is critical in ensuring equipment life and optimum boiler performance.

Note: A layer of soot or scale, only 0.03 inches thick, can reduce heat transfer by 9.5%. Moreover, a layer of 0.18 inches thick can minimize heat transfer by 69%

Minimizing Boiler Blowdowns

With too many TDS’s (Total Dissolved Solids) in the water, there are higher chances of scale accumulation and reduction in boiler efficiency. Consequently, there’s a necessity to maintain the solids below certain limits. As the TDS concentration increases within the boiler, the possibility of the dissolved solids precipitating out of the water and forming scale increases.

To deal with such situations, boiler blowdown, which is draining of the water, is done to remove the dissolved solids. Doing this helps in keeping the TDS concentration below the level where they will precipitate. To conserve water, chemicals, and energy, boiler companies must consider frequent and consistent small volume blowdowns.

Once the boiler breakdowns, it can cost thousands of rupees in getting its equipment repaired. Moreover, a considerable amount may also be incurred in business income losses and property damage. Not maintaining the boilers might even become a cause of losing the life of an executive and significant structural damage to equipment, facilities, and plants. Therefore, boiler companies in India must consider the maintenance of boilers; as when compared to a single instance of an unplanned plant shutdown, the cost of boiler inspections, support, and repairs is minor.