Brewery boilers require proper maintenance to perform optimally and reduce operating costs in the long run. It’s important to know how to address issues like leaks, mineral buildup and pressure loss. Keeping a maintenance log can also help you track trends and diagnose issues before they escalate, which can help ensure your brewery’s success.
Here are nine ways to service your brewery boiler and ensure top performance.
Several boiler parts can wear down over time, so it’s critical to catch issues when they’re still small to avoid substantial ones in the future. Forgoing maintenance can also lead to dangerous boiler explosions and injuries. For instance, the boiler may be damaged if water drops too rapidly without triggering the trip switch. Proper maintenance can avoid these costly and hazardous scenarios.
An example maintenance schedule might include:
Since insulation is not always effective, steam can condense easily in boilers. Steam traps are usually located at the bottom section of the steam line, keeping steam from getting out so you can conserve more energy and maintain efficiency.
It’s important to regularly check the steam traps for leaks or blockages, as they can prevent the steam from efficiently heating the boiler and lead to water hammer. Water hammer occurs when rapidly moving steam condenses into water and causes damaging pressure surges to the system. Overwork can also lead to more fuel and water consumption.
Regularly checking for steam trap leaks can keep your system running optimally and prevent further maintenance.
Regularly monitoring your boiler’s gauges can help you catch potential issues early. The gauges tell you if your boiler is operating within the correct pressure, temperature and water level ranges. They are also critical for preventing overpressure or overheating and damage.
For instance, if your old pressure gauge shows a low range even though your system is working, it might be outdated and need replacement. If you need new gauges, have professionals install and configure them. This way, you’ll know you’re getting accurate information to keep your boiler running properly.
Water often contains dissolved minerals like calcium, alkaline ions, magnesium, chloride and iron. These minerals can build up on the boiler’s inner surfaces and cause scale, a whitish substance that can obstruct heat transfer. Performing a weekly blowdown can remove the sediments to prevent scale buildup, maintain water quality and extend the life of your boiler.
It’s important to follow the manufacturer’s guidelines for your boiler to perform a blowdown safely and effectively. In general, the process includes reducing mineral concentration by draining water from the boiler. Then, you can replace it with new water that will typically contain fewer minerals.
It’s crucial to use a daily cleaning treatment to control corrosion, scale and microbial growth in your boiler. The type of treatments your boiler requires will depend on its specific setup, with specific types offering benefits like:
Consistently applying treatments can preserve the integrity of your equipment and ensure product quality. However, incorrect dosing can lead to damage or safety issues, so it’s best to contact a reliable water treatment company to determine the correct treatments required for optimal performance.
In addition to their closed design, boilers face a lot of pressure as the steam expands when it turns into water. If your boiler is losing pressure, this usually indicates a leak in the system. Be sure to monitor your boiler’s pressure gauge each week. Ranges should be within the green, while red ranges signify critical scenarios.
Check the valves and tank’s exterior where leaks are most frequent. Note that cold feedwater could reduce steam production if your tank has an on-off water feed, resulting in temporary pressure drops. An undersized heating element can also make it challenging for the water to boil and generate enough steam, resulting in low pressure.
Repair steam or water leaks promptly before they worsen. Leaks can release steam and water and potentially let contaminated air and water into the boiler. This can lead to corrosion, damage, microbial growth, and wear and tear. To check for leaks, do the following:
As part of your regular maintenance, it’s best practice to keep a maintenance log. This way, you prevent specific maintenance needs from slipping through the cracks, and you can record maintenance details you perform on your boiler. A log can also help you identify and track needs to set up the ideal maintenance appointment intervals.
In the event of an issue, you can scan previous maintenance activities for problem areas and check these spots for malfunctions. Ultimately, a maintenance log can help you diagnose issues before they worsen and cause emergency shutdowns.
It’s important to know when to call for professional assistance when servicing your boiler. While you might be able to address minor issues yourself, significant problems like leaks, pressure loss, gauge issues and extension scaling will require a professional to fix them accurately. Working with a reputable company can give you confidence that your water is treated properly, keeping your boiler in peak shape.
Ultimately, boiler maintenance is a major contributor to the success of your brewery. Regular boiler maintenance helps prevent unexpected breakdowns, keeps repair costs down and ensures your boiler runs at peak performance.
Chardon Laboratories offers several types of brewery boiler water treatments to eliminate scaling, prevent corrosion and keep your systems operating efficiently. We provide a complimentary assessment to determine your brewery boiler’s condition and service needs.
From there, our highly experienced technicians will apply superior clean systems. We also ensure the long-term performance of your brewery boiler by offering ongoing maintenance at a fixed price.
For dependable brewery boiler treatment, contact us today.
