At limpiezas técnicas industriales we offer you the maintenance of steam boilers, which require maintenance and attention for their correct operation.
Below is a guide to the annual maintenance procedure.
Presentation pdf boilers
MAINTENANCE OF A STEAM BOILER
Boiler maintenance is an important process that should be done on a regular basis, here are some specific recommendations to keep in mind when doing so.
DAILY MAINTENANCE
Clean the boiler burner nozzles.
Check the compressor lubricant level in the air-oil tank. It should be at 1/2 level, i.e. within the middle third and if it is lower, bring it up to level.
BLEED THE BOILER AT LEAST EVERY EIGHT WORKING HOURS, BOTH FROM THE BOTTOM BLEED AND FROM ITS LEVEL CONTROL COLUMNS. THIS IS DONE BY RAISING THE WATER LEVEL TO 1/2 GLASS AND PURGING UNTIL THE FEED PUMP STARTS. WE RECOMMEND THAT YOU CONSULT YOUR WATER TREATMENT EXPERT IN THIS MATTER AND IT IS VERY IMPORTANT TO FOLLOW THEIR INSTRUCTIONS AS WELL AS FOLLOW THE INSTRUCTIONS ON BOTTOM PURGES AND LEVEL CONTROL SENT BY THE MANUFACTURER WITH THE OPERATING MANUAL. READ AND FOLLOW THE INSTRUCTIONS ON THE WARNING PLATE ON THE SIDE OF THE BOILER.
Also check that the pressure indicated by the fuel inlet pressure gauges, the pressure at the metering valve and the fuel outlet pressure are as stated in your Operating Manual.
Check whether the atomising air pressure is correct.
Check and record flue gas temperature.
Take flue gas analysis and record in logbook.
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MAINTENANCE EVERY THREE DAYS
Check that the steam heater trap is operating correctly.
Clean the fuel filters on the pump suction.
MAINTENANCE EVERY EIGHT DAYS
Check that there are no gas or air leaks at the gaskets of both covers and rear sight glass.
Check the belt tension at the compressor.
Clean the lubricant filter, which is glued to the compressor.
Wash the filters, both the pump inlet filter and the water inlet filter to the condensate tank.
Clean the gas pilot electrode.
Check that the thermostatic switches on the fuel heater operate at the temperature at which they were calibrated at start-up. Refer to your Operation Manual.
Inspect the water feed pump glands.
Clean all water, fuel oil and lube oil filters.
Test operation for flame failure.
Check burner conditions, pressure, temperature, etc.
Check pump inlet and shutdown levels, making use of the boiler bottom bleed valves.
Make sure that the photocell is clean, as well as the tube where it is placed.
FORTNIGHTLY MAINTENANCE
MONTHLY MAINTENANCE
Check that the water levels are as indicated: 58 mm (2 ¼”) maximum level. 45 mm (1 ¾”) pump start. 32 mm (1 ¼”) low level cut-off.
CHECK THE LOW LEVEL BY LOWERING THE SWITCH ON THE FEED PUMP. WATER WILL DECREASE IN LEVEL AS IT EVAPORATES AND IF AT 32 mm (1 ¼”) IT DOES NOT CUT OFF THE LOW LEVEL, STOP THE BOILER IMMEDIATELY AND INSPECT THE THREE-WIRE MERCURY BULB (BOILER SIDE) AS WELL AS ENSURE THAT THE FLOAT IS FUNCTIONING PROPERLY AND THAT THE COLUMN IS FREE OF SLUDGE OR BUILD-UP.
Check the voltage and loads taken by the motors.
QUARTERLY BOILER MAINTENANCE
Observe the temperature of the boiler flue gas outlet thermometer, when it is 80°C above the saturated steam temperature, this indicates that the boiler is sooted and should be cleaned.
It is also advisable to uncover several turtles or registers in the middle and at the bottom of the boiler to check the water side of the boiler for internal cleanliness. Call the water treatment technician.
Every time the chimney is swept, it is advisable for the best preservation of the refractory, to grout it with refractory mortar, both to the back cover and to the firebox refractory. Change the gaskets.
Slightly pull the levers of the safety valves to allow them to escape and prevent them from sticking to their seat.
SEMI-ANNUAL BOILER MAINTENANCE
Check fuel pump speed reducer oil level.
Check the gaskets of the water feed pump stuffing box. If dry, replace with new ones.
General cleaning of the flame programmer contacts and starters with a clean piece of cloth, moistened with carbon tetrachloride.
No later than three months after initial start-up of the boiler and thereafter, as conditions require, the boiler should be cooled and dried, the covers removed and the interior flushed with pressurised water. Pipes and mirrors should be inspected at the same time for scaling. The effectiveness of the water treatment and the percentage of make-up water required will determine the next cleaning periods. The service of your water treatment expert should include inspections inside the boiler as well as periodic water analysis.
Inspect the flux tubes on the soot side and clean if necessary.
Inspect furnace refractory material and rear door.
Clean cracks and remove loose refractory material. Coat it with an air-curing refractory cement; the period of this coating varies with the type of load and operation of the boiler and should be determined by the operator when opening the doors for soot cleaning.
Check your drive belts for proper tension.
It is advisable to wash the boiler internally. To do this, remove the pressure gauge reducer on the tee at the outlet of the feed water pump and fit a reducer to the size of the hose to be used. Before all this is done, the boiler is cooled down by lowering the pressure and circulating the water, purging it to allow cold water to enter, and so on, until it is completely cold. The cooling operation should be done with rest periods of 20 to 25 minutes so that the cooling is not abrupt and damages the fluxes. The water is then completely drained and all turtles are removed. Once the hose is attached to the pump, the water inlet valve to the boiler is closed and when the pump is turned on, water comes out of the hose at high pressure. This jet of water is used to wash the inside of the boiler, and the hose is then passed through all the hand holes until it is very clean. The turtles and their seats in the boiler are cleaned thoroughly.
Check the cleanliness of the control columns and the water inlets of the feed pump and injector.
Check and flush the pressuretrols 1es, the entire pressuretrol line and the pressure gauge line.
Refresh the ropes to the turtle screw and put graphite with oil on them to prevent them from sticking.
UNCOVER ALL CROSSES AND CHECK THAT THEY ARE CLEAN. CLEAN AT LEAST EVERY SIX MONTHS.
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