Commercial and industrial boilers can last a long time if they are properly operated and maintained. However, component or system failure can lead to operational downtime as well as a costly system repair or replacement. Here are five common causes of boiler failure and what you can do to prevent them.
1. Creeping corrosion
Corrosion can occur in various parts of a boiler system, including the heat exchanger, pipes and tank. It's typically caused by the interaction of water, oxygen and heat. Corroded components weaken the structural integrity of the boiler and can lead to leaks, system breakdowns and safety hazards.
2. Pressure problems
Boiler systems operate under specific pressure levels. If pressure levels exceed the recommended range due to malfunctioning pressure relief valves, faulty controls or other issues, the boiler can fail. High pressure can cause leaks or ruptures, while low pressure can lead to inefficient operation and potential damage to the boiler.
3. Overheating
Overheating can occur when the boiler operates at excessively high temperatures, often due to malfunctioning controls, improper burner adjustment or lack of water flow. Such excessive temperatures can lead to cracks, leaks and even catastrophic failures. Adequate monitoring and control systems are essential to prevent overheating.
4. Fuel supply issues
Boilers require a consistent and adequate supply of fuel for proper operation. Issues such as fuel contamination, blockages in fuel lines or malfunctioning fuel delivery systems can disrupt the combustion process and cause the unit to fail. Regular fuel quality checks, proper filtration and maintenance of fuel supply components are crucial to prevent fuel-related failures.
5. Faulty ignition and control systems
Ignition problems can prevent the boiler from starting up or cause intermittent shutdowns, while control system failures can result in improper temperature regulation, excessive cycling or complete system shutdown.
Other common causes of boiler failure include improper water treatment, wear and tear on aging components and insufficient maintenance and cleaning.
Prevent problems before they occur
All equipment must eventually be replaced, but you can reduce operating costs and extend equipment life through preventive maintenance and proper operation. The following measures will help improve boiler efficiency and performance.
- Regularly check water quality to help mitigate corrosion issues and implement proper water treatment with corrosion-resistant materials.
- Monitor burners and adjust to maintain proper air levels. Excess air can result in reduced operating efficiency and overheating of boiler components.
- Inspect and test boiler controls for performance on a weekly or monthly basis, depending on the size and function of the boiler system.
- Verify the state of your boiler valves and seals. Make sure all valves and seals function properly at normal operating conditions.
- Monitor pressure gauges to ensure pressure levels remain within the manufacturer's recommendations.
- Perform regular fuel quality checks and inspections of fuel supply components.
- Regularly test the flow switch to ensure the boiler will shut down under no-flow conditions.
With a preventive maintenance program in place, you can prevent boiler system failures before they cost you money.