The regular inspection and maintenance of industrial boilers are crucial for ensuring the safe and economical operation of the equipment. Every user should establish a comprehensive maintenance and record-keeping system to effectively manage the daily operation of boilers, promptly identifying and resolving potential issues. The following content and recommendations apply to various boiler products; specific maintenance or operational methods can be found in the maintenance manuals provided by the manufacturer.

Daily Operation Monitoring of Boilers

1. Pressure Monitoring

  • Continuously monitor boiler pressure.

  • If the pressure gauge shows a pressure exceeding the design limit and the combustion has not stopped or the safety valve has not opened for venting, immediately stop the combustion, clear the fire source inside the furnace, and open the external vent valve or pull the safety valve handle for emergency venting.

  • In case of pressure anomalies, immediately stop the combustion, open the external vent valve for emergency venting, check and eliminate the fault before resuming use.

2. Water Level Monitoring

  • Continuously monitor and observe the boiler's water level.

  • If frequent high/low water level alarms occur, stop the boiler and check for blockages in the steam-water connecting pipes and false water levels.

  • If water is being drawn too early or the water level continues to drop until it is no longer visible at the lowest point of the water gauge, take emergency measures to forcibly stop the combustion and clear the fire source inside the furnace, allowing the boiler to cool naturally.

  • Note: After a boiler has a low water level, do not immediately add water to it.

3. Temperature Monitoring

  • Regularly test the boiler's feed water and water quality.

  • Regularly calibrate temperature sensors and displays, and check for abnormal temperature increases in the flue caused by soot or scale buildup.

  • If the flue gas temperature exceeds the normal operating range by 30°C or an electronic alarm sounds, stop the boiler to check if the issue is with the sensing device or due to soot/scale buildup.

4. Water Quality Monitoring

  • Regularly test the feed water and boiler water quality.

  • Regularly check the operation of water softening equipment to prevent scaling and corrosion.

5. Auxiliary Equipment Monitoring

  • Monitor the operation of auxiliary equipment in the boiler system and address any abnormalities promptly.

  • Continuously monitor the operation of auxiliary equipment and promptly address any anomalies. Boilers and fuel/oil burners are equipped with various safety protection devices and program controllers, which must not be altered, dismantled, or damaged under any circumstances.

Daily Operation Monitoring Based on Boiler Type

1. Combustion Control

  • Except for oil/gas boilers, other fuel industrial boilers should not operate under positive pressure in the furnace to avoid damaging the equipment and causing personal injury.

2. Equipment Inspection

  • Fans and Pumps: If vibration occurs, stop the boiler and inspect, as this is usually caused by impeller wear, deformation, or soot buildup. Replace or clean as necessary.

  • Water Level Gauges, Valves, Pipe Flanges, Manholes, Handholes: Check for leaks and repair as necessary.

  • Electrical Components: Inspect for aging or loose connections.

  • Transmission Parts: Check for abnormal noises.

  • Burning Equipment: Check ignition, extinguishing, and startup for abnormalities.

  • Other Abnormalities: Check for unknown vibrations, noises, alarms, steam shortages, flameouts, etc., and report issues to higher authorities for diagnosis and determination of continued use.

3. Filter Cleaning

  • Clean the dust removal water filter every shift (if applicable).

Daily Maintenance Items

  • Lubrication Maintenance (Based on Boiler Type)

  • Chains (mechanical transmission base)

  • Fixed grate base

  • Slag remover

  • Feeding machine

  • Grate reducer

  • Feeding reducer motor

  • Blower, induced draft fan (with gearbox)

  • Other equipment requiring lubrication and oil changes

Specific Operations for Regular Boiler Inspections and Maintenance

Monthly Boiler Inspection (30 Days)

  • Check lubricating oil and replace it for equipment requiring machine oil and gear oil, suggesting the first replacement after 30 days of initial use.

  • Inspect water level gauges, valves, and pipe connections for leaks.

  • Clean equipment surfaces and prioritize inspections of prominent abnormalities based on daily monitoring records.

Quarterly Boiler Inspection (90 Days)

  • Repeat monthly inspection items and check electrical connections, instruments, and switches.

  • Clean the boiler's internal and water wall tubes of scale and sludge.

  • Test the operation of water treatment equipment, remove ash and sludge from the dust removal water system.

Semi-Annual Boiler Inspection (180 Days)

  • Repeat quarterly inspection items and inspect internal welds of the boiler, check the bearings of fans and electrical equipment, and assess the wear of impellers and housings for operational stability.

  • Check the sensitivity and reliability of the three major safety accessories (water level gauge, safety valve, pressure gauge), replace and clean water treatment media and resin.

  • Replace sealing materials damaged during maintenance.

Benefits of Regular Boiler Maintenance

Regular maintenance of industrial boilers enhances safety, improves efficiency, extends equipment lifespan, reduces operating costs, and ensures compliance with regulatory requirements. Neglecting maintenance may lead to equipment failures, energy waste, increased operating costs, and even jeopardize worker safety. Detailed inspection and maintenance schedules, maintenance history records, operator training, proper tools and equipment, and flexible maintenance plan adjustments based on operational conditions are essential for ensuring the safe and efficient operation of boilers.

How to Establish an Effective Maintenance Plan

Establishing an effective industrial boiler maintenance plan requires considering various factors, including the equipment model, usage environment, and operational load. Here are some recommendations for developing a maintenance plan:

  • Create Inspection and Maintenance Schedules: Based on the manufacturer's recommendations and actual operating conditions, create detailed inspection and maintenance schedules, including daily, monthly, quarterly, and annual inspection and maintenance items.

  • Determine Inspection Items: Specify the contents of each inspection, including pressure, water level, temperature, water quality, auxiliary equipment, and safety devices. The inspection items may vary for different boiler models.

  • Record Maintenance History: After each inspection and maintenance, record the results, identified issues, and corrective actions taken. These records help track the equipment's operational status and identify and prevent potential problems.

  • Train Operators: Ensure that operators have the necessary skills and knowledge to perform daily inspections and basic maintenance correctly. Regular training sessions should be organized to enhance the professional skills of operators.

  • Use Proper Tools and Equipment: Use professional inspection tools and equipment to ensure the accuracy of inspection results. For highly specialized inspection items, consider hiring professional maintenance companies.

  • Budget Planning: Include maintenance costs in the annual budget to ensure sufficient funds for regular maintenance work, preventing delays due to insufficient funds.

  • Adjust Plans Based on Operational Conditions: Flexibly adjust the maintenance plan based on the actual operating conditions of the equipment. For example, conduct inspections and maintenance in advance when anomalies or fault warnings are detected.

Conclusion

Regular inspection and maintenance of industrial boilers are not only critical for ensuring the safety and efficiency of operations but also for extending the lifespan of the equipment and optimizing operational costs. By implementing a comprehensive maintenance plan that includes daily, monthly, quarterly, and semi-annual inspections, operators can prevent potential failures, comply with regulatory standards, and achieve sustainable energy use.

A proactive and systematic approach to boiler maintenance is indispensable for maintaining the integrity and efficiency of industrial operations. We hope this guide provides valuable insights and practical steps to help you effectively manage and maintain your industrial boilers.

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