Annual Boiler Shutdown and Service Procedures
To keep your boiler operating efficiently, reliably, and safely, it is important to shut it down properly and take the necessary maintenance and repair actions. To identify potential problem areas that need attention, follow this inspection checklist during the annual shutdown.
Inspect all of the equipment in the boiler room. Walk around the boiler before looking inside. Check for “hot spots”, which may indicate compromised insulation or gasketing. Look at external piping, valving, feed system, pumps, and pump seals, and note any leaks. Listen for bearing or cavitation noise. Check the alignment of the pumps, motor assemblies and water softener.
Shut down and secure the boiler. Once the boiler is open, look for evidence of scaling or corrosion on the waterside, and clean or replace tubes as necessary. On the fireside, evaluate the condition of the gaskets, and replace any that are dried out, brittle, or cracked. Check the door refractory for cracks.
Check the burner-drawer assembly and burner housing. In the case of the burner housing, you are looking for evidence of cracking or warping from excessive heat. if you see cracking, bending, or deformation of the burner baffle or diffuser, replace it since it must be intact for proper mixing of fuel and air.
Look closely at the pilot tube. It contains the pilot spark electrode. If it is corroded or burned or the space between the tip of the electrode rod and the inner pilot tube is lacking, the electrode will not have sufficient intensity to ignite.
Next, closely examine the lower-water cutoff. Clean and inspect probes; if a probe is deteriorated, replace it. Verify wiring is not cracked or broken and terminal connections are clean and tight.
Lastly, direct your attention to the burner-management and combustion controls. If they are old and outdated, consider a programmable logic controller.
A boiler that is clean and operates properly is essential, but do not overlook support systems including:
Makeup-air louvers: Ensure they are clean. Dirty louvers inhibit the combustion air.
Valves and fittings: Repair leaks. Leaks require the introduction of cold makeup water into a system with additional health input and chemicals.
Chimneys and flues: Ensure chimney and flue terminations are clean and clear. Test mechanical vent systems for proper operation. An improperly operating vent system affects combustion efficiency.
Water chemistry: Verify water-testing equipment is calibrated properly and not beyond its expiration date. Improper water chemistry leads to scaling and corrosion.
In the final analysis, it is critical that an annual boiler shutdown be part of your standard operating procedures and that your technicians be trained to perform a thorough inspection and combustion tune-up.
Boiler maintenance requires an experienced service technician. To schedule a consultation or inspection of your system, call us at 714-999-1177 or email service@prostarmechanical.com