Boiler Annual Maintenance
The important thing in boilers is to produce energy at low cost and to use it correctly. Fuel costs are the most important expense item in businesses. Considering that energy is dependent on foreign sources in our country, it is understood that the cost of energy is much more important.
Boiler annual maintenance is very important in terms of generating energy and using it correctly. Boiler annual maintenance is very important in terms of both the boiler life and the life of other equipment.
When the annual maintenance of the boiler is carried out, we also take the safety measure of the operating system. Malfunctions may occur at any time in the boiler operating in normal regime. These include gasket bursts, furnace collapses, equipment failures. Explosion of the gasket in the working boiler means that the steam in the boiler is not intervened before it is completely discharged. This means that costly generated steam is wasted. It also means that the production stops due to the steam requirement of the process not being met.
During the annual maintenance of the boiler, manholes and hand holes of the boilers are opened and the lime and mud layer accumulated on the water side of the boiler is cleaned. Failure to clean the layer causes yield loss (3% yield loss per 1 mm layer). The reason for this is that the flame burning in the boiler heats the lime layer without penetrating the water. The flame will give the remaining energy to the water after the lime layer is heated. This means that more fuel is burned to produce the same energy.
In addition, intervention to boiler equipment during annual maintenance also protects businesses from more costly breakdowns that may occur in the long run.
In the boiler maintenance work, the sheet thickness of the boiler is measured from different points and corrosion tests are carried out. In boiler maintenance, all automation devices on the boiler are checked, cleaned and calibrated.
The maintenance of the burners that provide combustion in liquid and gas fueled boilers is also within the scope of our periodic boiler maintenance operations. In burner maintenance; By removing the barrel of the burners, the ignition and ionization electrodes are cleaned. Combustion heads are cleaned and fan control is done. The gas line is checked for general leakage, and the air-gas mixture is checked. Then, the burners are operated and the flue gas emission measurement is made and the measurement results are delivered to the relevant person. Burner maintenance should be done at least twice a year, especially during the summer and winter months.
Boiler Revisions
Deformations occur in industrial boilers due to operating conditions, lack of timely maintenance and usage errors. Pipe punctures and mirror cracks are among them. In these cases, instead of replacing the boiler, repairs can be made by choosing a boiler revision at more affordable costs. Change of flame smoke pipes, change of front-back-inside mirrors, change of boiler covers, furnace can be modified by expert teams, subjected to hydrostatic test and delivered to enterprises in a healthy way.
Steam boiler pipes can be punctured for several reasons:
- There are corrosive gases such as oxygen and carbon dioxide dissolved in the water. At high temperatures, these gases in the water separate from the water and are trapped in the lime accumulated on the heat transfer surfaces. The oxygen trapped in the lime layer stays in constant contact with the iron, and this causes rust formation in the boiler pipes and causes punctures due to oxygen corrosion.
- When the water in the boiler heats up and starts to evaporate, some of the substances in the water such as calcium, magnesium, silicon sink to the bottom of the boiler and stick to the surface where the heat transfer takes place and harden. This lime layer, which we call rust, prevents heat transfer and causes both pipes to be exposed to high thermal stress and a serious decrease in boiler efficiency. Boiler sheet and pipes exposed to high thermal stress will experience faster metal fatigue and lose their iron properties faster.
- By using pipes of a quality that is not suitable for the usage conditions during the boiler manufacturing, the pipes can be worn out and pierced in the short term.
While changing the boiler pipes; It should be cut in accordance with the technique on the mirror and removed without damaging the mirror. After the cutting, the burrs formed on the mirror surface and the inner wall of the pipe holes are cleaned by grinding and after the flame smoke pipes are removed, the lime and mud deposits formed in the interior of the boiler are cleaned with pressurized water. Then, special boiler pipes are placed and the pipes are welded one by one with high-strength electrodes. After the welding process is finished, the boiler is taken to hydrostatic test and leakage control is performed and delivered to the customer.