10 Signs That Indicates Boiler Replacement
Industrial Steam Boilers are indispensable for process operations. Boilers generate steam by igniting fuels and heating water. Steam is excellent for processing, heating, drying, and sterilizing purposes in industries as it has exceptional energy holding capacity, is easy to use, and is cost-effective to generate. It can be concluded that steam boilers are unarguably vital equipment in the manufacturing and process industries.
Plant managers take various measures to ensure that the boiler systems operate efficiently by regular maintenance and other practices. Although periodic servicing and maintenance contribute significantly to optimal productivity, there is a certain point in the boiler lifecycle, when it needs replacement. Boiler problems are inevitable and can be prevented or resolved. However, some signs indicate that the boiler needs replacement. They are as follows:
- Low Energy Efficiency:
Steam boilers’ efficiency is rated by boiler manufacturers that are usually higher than its actual efficiency. Yet, by following standard guidelines and regular inspections, process plants can achieve optimal efficiency. With many years down the line, boiler efficiency gradually starts decreasing, which indicates boiler replacement.
- Boiler Takes Longer to Heat Than Usual:
A steam boiler that operates properly can heat within a few seconds. But, if it takes several minutes for heating even after inspection and repair, it becomes necessary to consider replacing the boiler.
- Leakages in Boiler:
Leaks in steam boilers often indicate that it has neared the end of its lifecycle. Boiler leakages are a serious issue that should be addressed immediately. If overlooked, it results in hazardous consequences. Additionally, leakages occur due to broken seals or valves and may be expensive to repair. Usually, plant managers prefer boiler replacement to repairs during severe leakages.
- Increased Fuel Demand:
Optimum combustion is a sign of a properly functioning steam boiler. When the boiler fails to burn fuels completely, it indicates the reducing combustion efficiency of the boiler. The fuel is required on a larger scale because it is partially wasted as unburned and results in increasing the fuel costs of the processing unit. In such cases, a boiler replacement is necessary as there are no reparations for fuel loss.
- Boiler Flame is Yellow Colored Instead of Blue:
The yellow color of the flame indicates the presence of carbon monoxide. It is odorless and therefore, difficult to detect. Installing a carbon monoxide detector helps in alerting the carbon monoxide. Boilers should be examined immediately by professionals as they can result in catastrophic accidents. Carbon monoxide emission is also indicated by black soot.
- Operating Temperature and Pressure:
One of the significant indications of steam boiler issues is its failure to maintain the required temperature and pressure during process operation. The parameter displays the boiler performance by measuring the amount of steam generated at present compared to when the boiler was installed. In such cases, it is advisable to consider boiler replacement for efficient production.
- Boiler Needs Frequent Repairing:
Although periodic repairing and servicing are inevitable for boilers, the constant need to repair some components or others may pose a serious issue. Rather than spending considerably on frequent reparations, it is prudent to invest in boiler replacement to prevent recurring boiler issues.
- Boiler Parts are Not Available:
If the boiler parts are challenging to procure or no longer manufactured, it is a sign that the boiler is outdated. In such a scenario, it is ideal to opt for boiler replacement instead of retrofitting.
- Safety Parameters:
Safety of the operating personnel is a matter of high priority that must be ensured with regular inspection. If the boiler system indicates safety issues during the inspection, it is essential to replace the boiler immediately. Some of the notable signs of safety problems are:
Irregular Starting or Stopping of Boilers: It indicates that the operating controls and safety valves are not operating properly. Such issues need prompt resolution with professional assistance.
High Stack Temperature: Stack temperature exceeding the usual level is a sign of poor heat transfer and unsafe conditions. The primary reasons for high stack temperature are low-quality boiler water, poor combustion, or low water level.
Poor Combustion Tuning: Improper fuel flow and airflow can result in significant pulsations and surges.
- Boiler Age:
Investing in boilers is a decision that impacts productivity for decades. On average, a boiler operates effectively for 20 to 25 years. It is advisable to retrofit the boiler when it crosses 10 to 15 years. However, after 25 years, it would be ideal to consider boiler replacement for enhanced productivity, efficiency, and advancement.
Boiler Replacement or Retrofitting:
Plant managers often consider the benefits between boiler replacement and retrofitting. Although the decision depends on various factors and the condition of the boiler system, boiler retrofitting can boost its efficiency by 10% to 12%. Boiler replacement offers a higher level of efficiency and safety, depending on the boiler. In either case, boiler replacement and retrofitting can considerably increase the efficiency and productivity of boilers.
Since our inception in 1983, Rakhoh Boilers have emerged as one of the leading boiler manufacturers and service providers globally. We have successfully installed more than 3000 boilers in 26 countries worldwide. We provide the best boiler retrofitting and upgrading services along with various other boiler-related services like boiler automation, energy audit, steam trap assessment, annual maintenance contract, etc.
Explore more about our products and services at www.rakhoh.com
- Published in Boiler