While boilers may not be top of mind over the warmer summer months, Goodway Technologies is sharing a reminder that skipping boiler maintenance before the weather starts cooling down again can lead to unnecessary costs and potential repairs. Even just 1/8” of scale can increase fuel consumption by 8%, leading to significant financial losses for facilities that rely on boilers for heating and production.
A 450,000 million Btu industrial boiler operating at 150-psig steam and producing 45,000 pounds per hour could see annual fuel costs of approximately $3.6 million. A seemingly minor 1/32-inch layer of scale could add $72,000 to that total, based on data from the U.S. Department of Energy.
“Boiler efficiency isn’t just about performance—it’s about safety, equipment longevity, and cost control,” said Tim Kane, CEO and president of Goodway Technologies. “Ignoring buildup can lead to corrosion, tube failure, and even larger-scale equipment failure.”
Best Practices for Boiler Maintenance
To mitigate these risks, facilities should implement a comprehensive preventative maintenance program that includes regular boiler cleaning. Key steps include:
- Identifying Boiler Type: Cleaning methods vary between firetube and watertube boilers. Firetube units require dry cleaning with brushes and vacuums, while watertube boilers often need air motors due to complex tube configurations.
- Evaluating Environmental Factors: Fuel type, water quality, and seasonal usage all influence buildup rates. For example, natural gas burns cleaner than coal or fuel oil, and hard water increases scale formation.
- Conducting Visual Inspections: Regular checks using tools like video scopes help assess buildup and detect early signs of damage.
- Considering Chemical Cleaning: For hard-to-reach areas or stubborn scale, chemical descalers can restore efficiency.
- Monitoring Performance Metrics: Tracking CO₂, O₂, and flue gas exhausts, along with monthly utility bills, can signal when cleaning is needed.
Incorporating boiler maintenance into your facility’s regular preventative maintenance plan is a smart strategy for reducing operational costs and ensuring your boiler operates at peak efficiency. A wide range of boiler cleaning systems are available to meet specific needs, and selecting the right solution depends on several factors, including the type of boiler, the severity of fouling, and other system characteristics. Professional boiler service providers can help find the right solution for your facility.