To comply with Simple Pressure Vessels (Safety) Regulations, all commercial and industrial high-pressure steam boilers over 100°C must be checked by a licensed boiler contractor at least once a year, and undergo NDT (Non-Destructive Testing) every five years. It is recommended that businesses have preventative maintenance checks carried out by a licensed contractor twice a year to prevent breakdowns and production loss, as well as to conform with inspections, insurance policies and warranties.
Regular servicing of industrial steam boilers may seem a costly process, but the financial and operational benefits, including preventing disturbances, reducing boiler downtime and increasing efficiency, far outweigh the cost of this service.
The H.A. McEwen Service
McEwen Boilermakers carry out the risk assessment, preparation and testing of all types and ages of industrial boilers to comply with Pressure Systems Safety Regulations (PSSR). Liaising with insurance inspectors, our engineers carry out the following checks:
- Initial risk assessment
- Remove steam valves and mountings from the boiler
- Either return steam valves for overhaul and re-certification or carry out mobile valve servicing on site
- Remove front and rear smokebox doors
- Remove all man-lids and mud-lids
- Clean fireside and water surfaces
- Removal of limescale and deposits
- Supply new gaskets and ceramic joints
- Liaise with Insurance Inspectors
- Re-fit valves
- Boiler rebuild
- Steam test
If problems are identified, our qualified engineers can repair and replace equipment on-site, with a range of services including structural boiler repairs, D-Patches, Retubes and Valve Overhauls. All work will be checked by insurance inspectors before being hydraulically tested to 1 1/2 working pressure and NDT standard.
Undertake a Boiler Blowdown
Boiler blowdowns are the central element of boiler servicing and maintenance and are necessary to control concentration cycles and prevent dangerous sludge build-up. The production of steam can leave solids and residue at the bottom of the boiler, such as calcium, sulfates, and bicarbonates, which if left untreated by a blowdown, can lead to poor heat transfer, reduced boiler efficiency, and an increased likelihood of boiler faults.
Increased Energy Efficiency and Reduced Carbon Emissions
Regular servicing ensures that the combustion and burner of the steam boiler are modulating correctly, therefore helping to prevent the waste of harmful gases including Carbon Dioxide (CO2), Methane (CH4) and Nitrous Oxide (N2O).
Faulty boiler components can cause boilers to use more fuel, electricity and water to maintain the necessary pressure and heat for optimal operations. Water impurities can also lead to short cycling and wet steam, resulting in wasted energy, dangerous gases, and increased running costs.
Components checked by our engineers include, but are not limited to:
- Gaps in spark rods
- Cracks to tubes and tube sheets
- Faulty electrical connections to prevent overheating
- Irregular flue gas operations
- Hairline fractures in ceramic retainer
- Lime deposits and buildup
Operator Health and Safety
The health and safety of employees is paramount. Industrial steam boilers use steam and hot water under large amounts of pressure, sometimes alongside oils and gases, which can explode, causing fatalities, injuries and property damage. Regularly servicing your boiler reduces these risks by ensuring that equipment complies with industry regulations and that any faults are identified, repaired and replaced.
Reduced Replacement Costs and Boiler Downtime
Industrial steam boilers are indispensable pieces of equipment that can lead to halting production and a loss of earnings if not regularly serviced.
Boiler failure often stems from corrosion, caused by the re-oxidisation of metal boiler components during exposure to water, which dramatically reduces the life of the equipment. Servicing can prevent and detect corrosion early, helping to avoid costly replacements or repairs, extend system life and increase employee safety by reducing the risk of explosions.
Save Water and Maintain Water Quality
To ensure optimal performance, boilers should use water that does not contain any oils or impurities. Wet steam, caused by a build-up of water impurities, forces the burner to operate for longer periods as it does not heat as efficiently or quickly, whilst short cycling affects the overall performance of your boiler and is a sign that the water contains oil. Through undertaking regular servicing, the water inside the boiler can be checked and tested, ensuring that high levels of performance and efficiency are maintained.