Understanding the Different Types of Steam Boilers Used in Australia sadsad

Steam boilers provide a solid backbone to many industries in Australia. With these boilers providing critical heat and reliable power for a vast array of applications from manufacturing to healthcare, they remain an integral and versatile piece of equipment. However, it is important to note that not all steam boilers are created equal, and in fact, there are different types of boilers designed to suit the needs of different industries and applications. This article explores the different types of steam boilers, including their characteristics, applications, and advantages. Then, keep reading to discover where to find professional steam boiler maintenance for your boiler.

Fire-Tube Boilers

Perhaps among the most recognisable type of steam boilers, fire-tube boilers are made up of a large cylindrical vessel that is filled with water. This is surrounded by tubes that carry hot gases, and as these gases pass through the tubes they transfer heat to the water, which generates steam. This type of boiler is relatively compact and is often used in smaller industrial facilities, like breweries. This is because fire-tube boilers can rapidly generate steam, and they can also cope with varying load demands.

Water-Tube Boilers

In contrast to the fire-tube boiler, water-tube boilers actually operate on a different principle. Featuring a network of water-filled tubes, these are surrounded by a shell containing hot gases. The combustion gases pass through these tubes, heating the water and producing steam. Water-tube boilers have a great reputation for their high efficiency, and ability to handle higher pressures. That means that the water-tube boiler is often used in industries such as large-scale manufacturing, where consistent and high-capacity steam and power are required at all times.

Packaged Boilers

Packaged boilers are factory-assembled pieces of equipment and they are designed to be installed quickly and operated easily. Offered in various configurations, including fire-tube and water-tube, they are a great option for businesses or industries that have limited space or resources. Packaged boilers can often be found in places like hospitals, schools, or hotels, or in addition, in small industrial settings. This is because these boilers are able to provide reliable and efficient steam generation.

Industrial Boilers

The term ‘industrial boiler’ encompasses a range of boilers that come in an array of designs, sizes, and capacities. These boilers are capable of meeting the demands of heavy industries, such as chemical manufacturing, petrochemical processing, and paper production. Industrial boilers come in both fire-tube and water-tube types, and they often feature emission reduction technologies, advanced control systems, and heat recovery components. Able to handle processes as well as high steam pressures, which is why they are designed for industrial applications.

Electric Boilers

Electric boilers generate steam by heating water using electric resistance heaters. They are able to offer precise temperature control as well as precise pressure control, which makes them suitable for applications that have stringent requirements. Importantly, these steam boilers are a great environmentally friendly option, as they produce zero emissions at the point of use. Electric boilers can often be found in research facilities and laboratories. This is because these industries have an essential requirement for compact and pollution-free steam generation.

Biomass Boilers

Biomass boilers utilise organic materials like wood chips or agricultural residue. The combustion of these biomass materials releases heat, and this heat is transferred to water, in turn generating steam. These boilers are also a very sustainable option, as they produce reduced greenhouse gas emissions. Biomass boilers are often used in some manufacturing industries, the forestry sector, or else in other sectors that are looking to transition to renewable energy sources.

Condensing Boilers

Condensing boilers are designed to extract additional heat from the flue gases, which allows for increased efficiency. A condensing boiler cools the flue gases to the point where water vapour condenses. This in turn releases latent heat. In industries such as food processing, condensing boilers are used due to the fact that they promote high thermal efficiency, and they also have a reduced impact on the environment.

Waste Heat Boilers

Waste heat boilers recover heat from industrial processes that would otherwise be wasted. These boilers are able to capture the residual heat from processes like exhaust gases, heat generated during chemical reactions, or high-temperature flue gases. They are often used in steel production, chemical processing, or cement manufacturing as these are industries that seek to maximise energy utilisation and minimise waste.

Do You Need Steam Boiler Maintenance?

Look no further than Tomlinson Energy Service. Backed by over 100 years of engineering and service experience, we know that steam boiler maintenance is critical to their efficient and safe operation. We are proud to offer you exceptional experience in maintenance, as well as steam boiler installation and repair. Plus, if you need to purchase a steam boiler, then you are in the right place.

When you need steam boiler maintenance, repair, or installation, call us at your state-specific telephone number, or fill out our online contact form and we will be happy to get back to you.

3 More Facts About Steam Boilers Explained sadsad

Because of our expertise in the boiler industry, we’re passionate about sharing gas burners and steam boiler facts and information with you. Maybe you’re an industrial history buff, or perhaps you’re in the boiler industry yourself. Maybe you’re just interested in knowing more about the piece of machinery that helps to power so many other industries, from brewing to food production, to healthcare. Regardless, keep reading to find out more about the steam-powered boiler, and to find out about where to go for the best in boiler maintenance and expertise.

Early Steam Boilers

The origin of the boiler can be traced back to England in the 17th century, with the inception of the very simple kettle boiler. The kettle boiler was just water, heated over a fire, which was then converted into steam through the heat.

Jump forward to the late 19th century, and it is widely accepted that the first people to patent a boiler were George Babcock and Steven Wilcox. Later, these men founded the Babcock and Wilcox Company in New York, USA. The Babcock and Wilcox company’s main venture was manufacturing boilers that were fuelled by coal and fed by hand.

Later, one of O.C. Barber’s companies The Stirling Boiler Company started to make boilers, and eventually, the Stirling Boiler Company would merge with the Babcock and Wilcox Company. They would be one of the major steam boiler manufacturers of their time, with their product the H-type Stirling, which was able to produce 50,000 pounds of steam per hour.

Boilers in the Industrial Revolution and Beyond

Boilers were a big feature during the industrial revolution, which was a time of incredible change and progress in manufacturing processes. A major advancement in the industrial revolution was the steam engine which was powered by a boiler.

The reason the steam engine was such a big part of this period of time and was so important is because it allowed for more reliable transportation of people, goods, and materials. Take a look at this Wikipedia page on steam engines to find out more about how boilers contributed to transportation at the time.

Further, in the period that followed the industrial revolution steam-powered boilers were prevalent during World War 1 and World War 2, in the form of steam-powered ships and boats.

The Major Components of Steam Boilers

The Burner: The burner is the component of the boiler system where the fuel source, (whether that is oil, or coal, for example), meets the air and combusts.

The Combustion Chamber: This is a chamber that is traditionally made from cast iron, and its purpose is to burn the fuel inside in order to heat the water. The reason this is made from cast iron, or otherwise steel, is that the material needs to be able to withstand extreme temperatures – up to several hundred degrees!

The Heat Exchanger: The heat exchanger does what the name suggests: it transfers the heat that has been produced in the combustion chamber to the water. They are mostly made of stainless steel, as this material does not rust, and will not corrode.

Bonus Component: The Safety Valve

In general, a safety valve is a particular type of valve that acts as a fail-safe in a piece of machinery or equipment. This means that it’s a feature that will respond to a failure in the machinery in a way that will prevent or minimise harm to any people, or to the environment around the machine.

This makes the safety valve an incredibly important device. First developed and put into use during the industrial revolution, now they either come with a spring mechanism, balanced bellows or are pilot operated.

In steam boilers, the safety valve acts to relieve excess pressure that is in the boiler. This happens by the safety valve opening to release an amount of fluid from within the boiler once a particular amount of excess pressure is achieved. It can be catastrophic if the boiler reaches a level of pressure beyond the safe level, and if there is no safety valve to relieve this pressure. Check out our guide to these pressure valves to find out more about their importance to boilers.

Do You Need Boiler Maintenance Experts?

That’s what you’ll find at Tomlinson Energy Service. Backed by more than 100 years of engineering and service experience, we pride ourselves on providing exceptional customer service, as well as professional expertise in maintaining, repairing, and installing steam-powered boilers. Plus, as a member of the Environmental Group Limited (EGL), here at Tomlinson Energy Service, we are committed to sustainability and the protection of the environment.

When you need boiler maintenance or boiler repair, make sure to call us at your state-specific telephone number, or fill out our online contact form, and one of our industry experts will get back to you.

4 Questions About Steam Boilers Answered sadsad

Here at Tomlinson Energy Service, we are passionate about steam boilers – they are a major part of our business. We are experts at boiler maintenance, repair, and installation, and we thrive on being Australia’s foremost packaged boiler and energy system specialists.

Whether you’re a history or engineering buff, a boiler worker, or in the market for a boiler, you might have a few questions about how they work, what their function or role is in our lives, or where to look for professional boiler expertise. Keep reading to find the answers to all your questions!

What is a Steam Boiler?

In essence, a boiler is a piece of machinery characterised by a pressurised vessel that transmits heat to water, in order to produce steam. This sounds simple enough, but a boiler is actually made up of many different parts that function together to produce the steam for its required purpose. You can read on to learn about how steam-powered boilers work, but also make sure to check out the history and various different types of boilers in our comprehensive article all about them!

How do Steam Boilers Work?

So far, we’ve learnt that boilers produce and store steam. But how do they do this? It’s actually quite a simple principle, hence why they have such a long history, dating all the way back in their simplest form to the 17th century! As we’ve outlined, one of the major features of boilers is a vessel that holds water. The vessel is then heated by a fuel, (this is generally Natural Gas ), which then produces hot gasses. These gasses heat the vessel and the water inside which leads to the production of steam.

Steam, as the name suggests, is essential to the function of this piece of machinery, as it is then funnelled through pipes to be used for different purposes.

What Are Steam Boilers Used For?

Maybe you’re familiar with boilers in theory, but are you aware of the functions they perform? Given they have such a long history, it’s no surprise that steam-powered boilers have had, and still have many uses in the world around us. One of the major functions of boilers through the years has been to heat homes, as well as workplaces like offices, hospitals, and retail spaces. In addition, it will be no surprise that the steam-powered train, (also known as a locomotive), is powered by a steam boiler!

Read on to find out some of the more surprising things that are powered by these boilers.

Aquariums: Did you know that aquariums rely on boilers to properly regulate the temperature in their tanks? A large aquarium like the one in Melbourne’s CBD has numerous exhibitions with many tanks containing a variety of different species of sea- life. These animals require differing water temperatures in order to survive, and the system maintaining and regulating these temperatures is often a boiler powered by steam.

Labs and Hospitals: These essential clinical and medical facilities also rely on boilers for different functions. A large use for boilers in these settings is heating, as they are often large facilities that can be quite cold, so they require a large amount of reliable heat to warm them. In addition, steam-powered boilers can be used for sterilisation purposes, which is critical to the safe operation of a hospital or laboratory.

Brewing: Are you a beer fan? It might surprise you to know that one of the most important features of a brewery is a steam powered boiler. As beer is brewed in large vessels, these require efficient and complete sanitisation. What piece of machinery powers the sanitisation process? You guessed it: the steam boiler.

How Can I Be Safe Around Steam Boilers?

Like any piece of machinery, steam-powered boilers pose a safety risk and as such, safety must be the top consideration at all times. There are particular safety protocols that you must be aware of when it comes to these boilers, and it’s important that you understand your Occupational Health and Safety obligations and responsibilities. It is essential that you deal with experts in steam boilers, and that you follow the safety rules and regulations laid out by your state.

Looking for a Steam Boiler Expert?

Here at Tomlinson Energy Service, we maintain, repair, and install steam boilers with reliable and personal service. A proud member of the Environmental Group Limited (EGL), Tomlinson Energy Service is committed to sustainability and is backed by more than 100 years of engineering and service experience.

For all your steam-powered boiler needs, contact us by calling +61 3 8560 0419, or by filling out our online contact form and we will happily take care of your enquiry.

Steam Boilers – What Are The Main Types? sadsad

Boilers are a type of heating system that can be used to generate high-pressure steam-based energy. There are a variety of different types of steam boilers available, categorised by factors such as size, portability, how they function and more. What they all have in common is their use of fuel, to heat up hot water or generate steam. A common categorisation of boilers into ‘fire’ and ‘water’ boilers. This distinction refers to the design and heating features of the boilers.

A Short History of Boilers

Early steam generators were little more than kettles heated with a fire underneath. These were referred to as shell boilers and became common in the 17th century, almost 2000 years after Hero’s the novelty machine, called an aelopile, (alo-op-illy), or rotary steam engine was invented. The concept of steam being used to do useful work developed until, in the early 1600’s, Brance, an Italian engineer developed the first workable steam turbine. From this point on the demand for higher pressure and higher temperature steam increased.

In 1740 John Allen realised that the way to increase boiler efficiency was to increase the contact time between the hot gas and the heating surface and he developed a shell boiler with a smoke flue winding back and forth through the shell. He also conceived the idea of a bellows in order to force air through the boiler and thus overcome the problem of oxygen depletion in the furnace, probably the forerunner of the modern forced draft fan. Then In 1804 Richard Trevithick designed a simple fire tube boiler with a cast iron shell and dished ends and this became the basis for further development resulting in the modern multi-pass fire tube boiler of today.

Engineers, even during the early stages of the development of the fire tube design, were considering other possibilities. Williams Blakey’s basic water tube steam generator, (1766) was the predecessor of the early water tube boiler and as the requirement for higher pressure steam boilers increased, engineers recognised that the shell boiler had limitations and the real development of the water tube boiler began. The first truly successful water tube design came in 1856 when Stephen Wilcox developed his boiler with improved water circulation and increased heating surface. This boiler was inherently safe and development continued rapidly, culminating in the highly complex modern water tube boiler that is capable of operating at high pressure and temperature.

Fire Tube Boilers

Fire tube boilers are sometimes referred to as shell boilers or drum boilers. The name is derived from the fact that; a), the hot combustion gases pass through the tubes and the medium to be heated passes around the tubes or, b), the heating surfaces are contained within a “Shell” as in a “Shell and Tube” heat exchanger or a “Drum”. The maximum output and pressure rating of a fire tube boiler is usually limited by the maximum furnace thickness allowed by the Code, (22mm), which limits the diameter and pressure.  In addition, a large diameter drum, (big enough to contain a furnace and tube bundle for the required heating surface), would need a disproportionate drum metal thickness in order to achieve the strength required, thus leading to increased manufacturing costs and weight.

A simple shell boiler comprises a drum into which is fitted a furnace tube, (housing the burner or fuel stoker), a rear combustion chamber or turning chamber, a bank, (or multiple banks) of tubes, referred to as smoke tubes or convection tubes and one or more smoke boxes or turning chambers. The tubes may be expanded or welded into the end plates of the shell, (the tube sheets), and there will be some heavy walled tubes called stay tubes and some solid bars called stay bars connecting the front and rear tube sheets. These are welded into the tube sheets and provide structural strength to the boiler. The boiler water is controlled at a level just covering the heated components, which allows some space for the collection of the steam. Various components are fitted to the drum to control the flow of feed water and steam and to protect against overpressure.

1      Wet and Dry Back Boilers

Shell boilers may be wet or dry back, (Fig 1).  A wet back boiler will have the rear combustion chamber water cooled thus increasing the heat exchange surface and eliminating the need for refractory to protect the rear outer casing of the boiler from excessive heat.

2      Multi Pass Boilers

Modern boilers are generally two or three pass (Fig.2), i.e. the combustion gas will pass through the furnace, (first, pass) and a number of tube banks, (the second and third passes), before exiting through the stack. Some types, referred to as Reverse Flame or Return Flame (Fig.3), have a furnace that is closed at one end, which forces the combustion gas to return upon itself before passing through a tube bank and exiting via the flue.

Two Pass Dry Back Boiler (Fig.1)
Two Pass Dry Back Boiler (Fig.1)
A three Pass Wet Back Boiler (Fig.2)
A three Pass Wet Back Boiler (Fig.2)
Reverse Flame Boiler (Fig. 3)
Reverse Flame Boiler (Fig. 3)

Water Tube Boilers

Water tube boilers (Fig. 4 and 5) are so called because the water passes through the tubes and the hot combustion gas passes around the tubes. Generally, a water tube boiler will have one or more drums into which the tubes are terminated. The configuration of the boiler will vary between types and manufacturers but generally, TES service technicians will be involved with bi-drum boilers such as the SD and SDGL  designs or the Tomlinson “O” Type In these types the bottom drum acts as a reservoir for storing a reserve of water and the top drum a separation point for the steam and water factions and as a vessel in which the level of water in the boiler can be controlled. Other configurations include “A” types in which two bottom drums are connected to a single top drum and single drum types in which the tubes themselves form the storage component of the boiler. Circulation may be natural or forced and is an important facet of the design of the boiler.

Because the pressure parts are relatively small in diameter a water tube boiler is able to operate at a much higher pressure than a shell boiler. Water tube boilers may be gas, liquid or solid fuel fired. Such fuels as coal, wood waste, bagasse, black liquor, sludge, industrial waste, municipal waste or a combination of different fuel types can be used and may produce up to 4,500 tonnes of steam/hr at up to 310 bar and 590oC.

Basic Water Tube Design (Fig.4)
Basic Water Tube Design (Fig.4)
Typical D Type Boiler (Fig 5)
Typical D Type Boiler (Fig 5)

Tomlinson Energy has been one of the leading names within the Australian steam boiler industry for over a century. Boilers are an integral part of many businesses, so if you need help with installation, repair, or maintenance, get in contact to find out how we can support your business. Or check out our range of fire and water tube steam boiler products available today. With over a century of industry experience, Tomlinson Energy is a company you can count on to provide top-tier boiler services.

Get in contact with us at Tomlinson Energy Service via our contact form or call us at +61 3 8560 0419 to ensure smooth steam water boiler service and repair.  

Celebrating 40 Years of Boiler Service sadsad

Tomlinson started in Western Australia, in 1892. This year will be our 130th year of existence and a significant milestone in the company’s history. One of our dedicated employees, Darryl Burnes, has been part of the Tomlinson Team for 40 of those years! Darryl applied for the job in February 1982 after a suggestion from his brother-in-law, who was a service manager at the time. His application was successful and began his long journey as a tube cleaner. In 1982, boilers in the Sydney area were being converted from diesel oil firing to natural gas. There was plenty of boiler work there for Darryl to do.

At the time, Tomlinson was known as ‘Tomlinson Steel PTY LTD’ and was located at Sydney Street, Marrickville. The area would not be recognisable today. Once the centre of the industry, Marrickville is now home to large apartment complexes. The business was bought out by Clyde Industries and moved to Granville, this was followed by a sale to Centurion Industries, in the 90’s, further relocating operations to Smithfield. Darryl moved with the company. By the ’90s, tube cleaning was almost a thing of the past. Darryl moved on to doing refractory repairs, brickwork and boiler re-tubing. Rather than going home at night covered in soot, he was going home covered in refractory concrete dust.

Later, Tomlinson was bought out by RCR and rebadged to RCR Energy Service. The business travelled to Wetherill Park and then to Seven Hills. Darryl continued expanding his skills. He became further involved in stock and stores, on-call servicing, annual boiler services and scheduling work when service coordinators were away.

In 2019 RCR Energy service was bought by EGL Group. It took on the name of Tomlinson Energy Service. This meant Darryl was relocating again. In total, he relocated over seven times and watched the company transition across five different owners during his 40 years of service. Darryl has worked under eight (8) different state managers, over twelve (12) service managers and over 150 fellow service technicians. He has seen off numerous CEOs. Too many to recollect.

Boiler technology has significantly advanced over the years, making Darryl a master of servicing many different types and models. He has gained a wealth of knowledge of boiler components and locations. If you are unsure of what boiler is at what site Darryl will tell you off the top of his head.

Darryl has described the current management team and work colleagues as the best he has worked with in his time at Tomlinson. However, after 40 years he is considering moving on. On behalf of everyone at Tomlinson Energy Service, I congratulate Darryl on reaching such a significant milestone. When he eventually decides to hang up the boots, we wish him all the best in his retirement.

Darryl Burnes 40 years in the boiler industry at Tomlinson Energy

Tomlinson Energy Service provides a complete repair and maintenance service for boilers 24/7, 365 days a year. Our experienced team of specialists will deliver unparalleled boiler repair and boiler maintenance service on-site to ensure your boilers continue to work at optimal capacity for as long as possible. 

Get in contact with us at Tomlinson Energy Service via our contact form or call us at +61 3 8560 0419 to ensure smooth steam water boiler service and repair.  

Maintaining Your Steam Boiler – Why You Should Do It and How? sadsad

Industrial steam boilers are commonplace across Australia and are found in essential systems in almost every industry, from hospitals to food processing. Boilers apply energy from sources such as coal, gas, or renewables to provide heat, hot water or both, and must do so reliably to keep processes running smoothly. Due to their importance, steam boiler maintenance is necessary for all industrial steam boilers if managers want to maximise uptime and minimise repair costs. 

steam boiler

Why Maintenance Is Important for Your Facility

Australian Standards AS2593 has a requirement for all steam boilers regardless of size to have regular service and safety checks – these can be five (5) weekly or three (3) monthly depending on the type of boiler you have installed.

The Standard sets out minimum requirements to ensure the safe operation of your boiler plant 

Steam boiler maintenance is critical for ensuring the optimal efficiency and safety of your facility. Following correct and regular steam boiler maintenance practices can prevent incidents from occurring and mitigate the chance of components failing (which can, in extreme situations, result in explosions). Proper maintenance of your steam boiler can also prevent hours or days of boiler downtime. Although maintenance works are an additional cost to the business, a well-maintained boiler with increased safety and reliability can reduce overall replacement and repair costs, avoid excessive and unpredictable downtime, and increase energy efficiency which reduces the consumption of resources. Thus, proper steam boiler maintenance can go a long way in not only keeping your steam boiler in working order but saving you money, extending its machine life, and avoiding catastrophic malfunctions. 

Best Practices for Maintaining Your Steam Boiler

Given the importance of steam boiler maintenance for operational efficiency and effectiveness, many industry experts recommend a maintenance plan that includes the following best practices: 

  1. Read the owner’s manual for the equipment

One maintenance tip that is often overlooked is ensuring you have read the manufacturing manual for the equipment you have purchased and installed. Paying attention to any specific instructions from the manufacturer and clarifying any questions you have with your steam boiler installers can go a long way. Having a holistic understanding of your unique boiler is important to ensure you’re not only maintaining and servicing it properly but also using it the right way to reduce the chances of malfunction or breakdown.

  • Monitor water quality and maintain proper water treatment processes

Although steam boilers are made of durable materials, corrosion and damage can happen to your boiler if the water flowing through your machine is not properly treated. Water that comes through your steam boiler contains impurities that can produce a hard scale that latches onto the metal and tubes of your boiler. This deposit build-up reduces heat transfer and causes corrosion – both of which will reduce the efficiency of your steam boiler and increase running costs. Ensuring the water inside your boiler receives chemical treatment can prevent non-condensable gases from getting inside the boiler and wreaking havoc. An example of this is oxygen pitting where dissolved oxygen in your boiler system attacks and corrodes the boiler’s metal surface. With sufficient damage to your steam boiler, a repair may not be sufficient, and you might spend more money replacing your entire steam boiler. 

  • Have a maintenance schedule and checklist

The best way to keep your units running optimally and avoid repairs is to continually monitor them and schedule boiler maintenance in advance. Your steam boilers should be regularly inspected by professionals for safety and identification of any weaknesses. Regular inspections can also identify areas of corrosion and threats of oxygen pitting. 

While most people think boiler maintenance can be left to professionals on a yearly or bi-annual basis, checking your steam boiler yourself on a daily and monthly basis can also help extend the machine life of your boiler. Some examples of daily and monthly preventative maintenance practices are listed below: 

Daily 

  • Inspect your boiler for leaking water 
  • Check temperature and pressure readings to make sure they are all within the designed range 
  • Listen closely for unusual vibrations or noises from the equipment
  • Perform bottom blowdown to remove sludge and sediment

Five (5) weekly or Three (3) Monthly

  1. Check pressure stat controls for correct operation.
  2. Remove, clean and adjust ignition electrodes.
  3. Open burner.  Check firebox and refractories. (only if cool)
  4. Ensure free operation of rotary or butterfly damper.
  5. Check burner linkage, locking screws and over-travel mechanism.
  6. Check burner controls and clean as required.
  7. Clean UV scanner cells and sight tubes and check operating voltage limits.
  8. Service sight assembly to ensure the gas-tight seal.
  9. Fire burner and check minimum pilot.
  10. Check all safety interlocks are operational.
  11. Check combustion and adjust to give maximum combustion efficiency.
  12. Check the condition of boilers and burners, in particular any sign of adverse wear and tear.
  13. Check filter elements and renew as required and approved.
  14. Report to a client on action taken and any general comments

Annually

  1. Carry out items 1 to 14 of the service visit.
  2. Open fireside and clean fireside of boiler tubes which comprises brushing and vacuum removal of soot. Excessive scale where present will be removed at an additional charge as per Tomlinson Energy’s standard rates applicable at the time.
  3. Inspect and repair refractories if necessary (patching where practicable with refractory compound).
  4. Reseal fireside.
  5. Check filter elements and renew the same as required.
  6. The annual visit for burners is as per the quarterly visit.
  7. Prepare boiler for inspection
  8. Assist boiler inspector as required.
  9. Report to the owner on boiler inspectors’ comments or requirements for repair or future operation

If you notice any problems or have any concerns, you should immediately report the problem to a service technician. In any case, the annual service should always and only be performed by an experienced service agency or qualified and licensed professional. 

Do you need an industrial steam water boiler serviced or repaired? 

Tomlinson Energy Service provides a complete repair and maintenance service for boilers 24/7, 365 days a year. Our experienced team of specialists will deliver unparalleled boiler repair and boiler maintenance service on-site to ensure your boilers continue to work at optimal capacity for as long as possible. 

Get in contact with us at Tomlinson Energy Service via our contact form or call us at +61 3 8560 0419 to ensure smooth steam water boiler service and repair.  

Tomlinson Welcomes Ignite to the EGL Group sadsad

The Environmental Group Limited (ASX:EGL) is pleased to announce the acquisition of Ignite Services Pty Ltd (“Ignite Services”). The acquisition includes all the assets of the business including working capital. The transaction will add significant strength to the EGL offering with a highly complementary service and product offering, while being earnings accretive for EGL shareholders. 

Ignite Services will continue to run as a standalone business within the EGL Tomlinson Energy Service division. The acquisition rationale is based on revenue synergies that can be achieved from complimenting and growing Ignite with the EGL infrastructure. No costs savings have been assumed. All employees, including the three current directors, will remain with the business with the opportunity to grow and develop their careers as part of a larger group. 

EGL Chief Executive Officer Jason Dixon said, “the acquisition will add further strength to our earnings while complimenting the Tomlinson Energy Services (TES) business with an expanded offering. With Ignite Services’ focus on combustion technologies and waste treatment technologies both EGL Waste and Water will benefit from the knowledge and experience Ignite brings to the Group.” 

What Industries Utilise Steam Water Boilers? sadsad

Industrial grade steam water boilers are commonplace across the entire Australian workforce, and essential in many key industries. Boilers apply energy from sources such as coal, gas, or renewables to heat water (or other applicable liquids) into steam. Industrial grade boilers serve similar functions to a regular residential hot water system or boiler; except with much higher pressure, greater heating and energy efficiency capabilities. They are used for heating/ cooling applications, power generation, high-pressure cleaning or cooking. Today we are going to look at several industries that require steam water boilers for everyday task completion. Utilise Steam Water Boilers?

Many industries require water boilers operating around the clock to maintain regular function. At Tomlinson Energy, not only do we provide regular industrial boiler installation and servicing within Australia, but we also offer 24-hour emergency boiler repair services, allowing your workplace to function normally, at any time of night or day.

Hospitals & Medical Industries

The medical industry utilises industrial grade steam boilers in a variety of sizes and settings. The high-pressure steam is used for cleaning and sterilizing throughout hospital facilities to maintain a medically sanitary environment. Running and heating a large facility such as a hospital also requires industrial boilers, allowing hospitals to regulate temperature and humidity within such a large facility. Hospitals require specific temperature and humidity levels for not only patient comfort but to keep the facility sanitary; preventing mould build-up.

Breweries, Distilleries

Breweries utilise steam water boilers for several key features throughout the alcohol distillation and brewing process. An industrial steam boiler allows for precise temperature maintenance and control for alcoholic solutions throughout the process, ensuring that the final product has the correct consistency, texture, and flavour profile. Steam is also utilised for sterilization and pasteurisation heating when the beer is transitioned into bottles or keg storage.  

Food & Beverage Processing

Food preparation and processing industries require a large amount of hot water throughout the manufacturing process. The most energy-efficient method of heating is with an industrial steam boiler. Steam and heat are used to reduce bacterial risk and sterilise food, so it is suitable for human consumption, reducing the spread of pathogens and disease. A faulty steam water boiler could result in a continual health risk for consumers, hence the rigorous standards that the food manufacturing industry must uphold.

Shared Residency Facilities

Housing complexes and residency facilities utilise industrial steam boilers for heating buildings; hot water for residents to use in their bathroom, kitchen, laundry, and shared spaces. Rather than having each resident have individual hot water and boiler systems, it can be more energy-efficient and cost-effective for landlords and builders to install compact industrial grade boilers to provide heating solutions for several floors of residents. Hot-water requirements would differ based on times of day when people are cooking, cleaning, showering, so a modular boiler that can regulate the heat at different times of day is required in this scenario. (Or the landlord will receive complaints about inconsistent water temperature.)

Laundry

Commercial laundry facilities consume large amounts of hot water and steam to fulfil the business’s basic daily cleaning tasks, running the laundry machines, steaming, and pressing clothes. Given a large amount of heat used in these facilities it is more economic and energy efficient to utilise an industrial grade boiler.

Textile / Paper Mills

Industrial boilers allow manufacturers to produce precise temperature and pressure at any point in time. This is essential during the manufacturing of textiles, as the dyeing and pre-treatment process requires hot water at a large scale.

It’s important to provide regular maintenance to your water boilers to ensure they function as intended without an unexpected lapse. Does your company need an industrial steam water boiler installed, serviced, or repaired? Get in contact with us at Tomlinson Energy to ensure smooth steam water boiler service and installation. We offer 24/7 boiler maintenance and repair because we understand the importance of steam water boilers in key industries across Australia. As a leading vendor of steam boilers, you can be confident that we have the perfect boiler solution for your building’s unique requirements.

If you would like to get in touch with our team today, then please call us on +61 3 8560 0419 or fill out our online contact form.

How to Prepare for a New Hot Water Boiler Installation sadsad

Whether you’re replacing an older boiler that no longer functions efficiently or you’re interested in upgrading to a more innovative model, boiler installation can seem like a daunting process. Hot water boilers are integral to keeping building and workplace temperatures at a comfortable level, so a properly functioning and well-maintained boiler should be a priority for all businesses and commercial buildings. Thankfully, the experts at Tomlinson Energy Service are here to help! Read on to learn the basic process and preparation tips for a seamless installation process.  

Choosing the correct boiler type

There are many types of boilers to choose between, so the boiler with the best performance will depend on your building’s needs. A boiler installer will typically ask about the building’s layout, utility connections, space availabilities, boiler room location, ventilation options and your hot water requirements, but you should also consider energy efficiency for a more cost-effective boiler. To find out the boiler solution best suited for your building, and whether to choose a conventional boiler or Condensing Boiler, consider reaching out to a specialist supplier and installation team.

Installing a new hot water boiler

The first step of a new boiler install is for a technician to visit the site, assess the boiler room’s space and building’s needs and plan the approach to this unique installation. This includes ensuring appropriate ventilation and clearances for the new boiler for safe operation and maintenance.

On the day, the technician will arrive and begin by removing the older system. Due to safety risks associated with liquid spills, electricity and high-temperature water, this includes taking the time to reduce the tank pressure and empty the water within the older hot water system before disassembling and removing it. Depending on the boiler, this may include additional plumbing or electrical work to better fit the needs of the new machinery. The new boiler will then be installed and tested for safety and quality.

Tips for a seamless boiler installation

To avoid any unnecessary tripping hazards, clear the hallway and entrance to the boiler room before the technician arrives. This includes removing items from walkways that could be damaged and ensuring non-slip mats are in place.

Boiler installation can also range from a few hours to a couple of days. This depends on more time-consuming and complex factors like moving the boiler location or removing an older, bulky system. During the installation, there may be disruptions to basic utilities like water and electricity, so it is recommended that sensitive electronics be shut down before work begins. For that reason, it might also be preferable to wait for appropriate weather to replace your boiler system to avoid any disruptions to your building’s heating.

The boiler installation process can also differ depending on the unique needs and issues of your building. This could include challenging or inconvenient access to the boiler room or the need for additional plumbing or electrical work. Your bespoke boiler solution might also require adjusting the existing plumbing to better fit the new installation. Thankfully, experienced technicians will be able to create a streamlined installation plan that’s efficient and minimises disruption.

Lastly, to ensure the longevity of your new hot water boiler, schedule routine maintenance and safety checks with an experienced technician. Regular maintenance will ensure that your boiler runs smoothly and extends the machine’s lifetime.  

Hot Water Boiler Installation-1

The difference of Tomlinson Energy Service  

Our installation team carry out all types of industrial and commercial boiler installation, both large and small. Our boilers are built to specifications to accommodate your precise requirements and physical footprints. This complete solution includes any electrical, mechanical or plumbing work and insulation.

As experienced vendors, we stock a range of hot water boilers and related parts and products. With over 100 years of premium repairs and installation services and a focus on quality and safety, no hot water boiler installation is too difficult for our talented team. 

In need of boiler installation?

The professional team at Tomlinson Energy Service are experts in the installation and maintenance of industrial and commercial boilers. Operating in Australia for over 100 years, our dedicated technicians are available for all your boiler service needs with tailored installation services and 24/7 boiler and gas burner maintenance and repair. As a leading Australian vendor of steam boilers, you can be confident that we have the perfect boiler solution for your building’s unique requirements.

If you would like to get in touch with our team today, then please call us on +61 3 8560 0419 or fill out our online contact form.

A Guide to Pressure Relief Valves in Industrial Steam Boilers sadsad

As experts in a wide variety of boiler systems, our team recognises that industrial steam boilers are only efficient if all their valves are well fitted and perform correctly. That means ensuring the valves are calibrated efficiently and in pristine condition to withstand the boiler’s pressure. It can be easy to miss when an industrial steam boiler needs routine maintenance, so it’s important to pay attention when your pressure relief valve opens and assess if this is a symptom of a greater mechanical issue.

The purpose of the pressure relief valve

Often situated on the top or side of a steam boiler, the pressure relief valve has a nozzle that releases pressure to avoid building up to unsafe levels within the boiler. If the steam boiler reaches a certain pressure or temperature above the desired levels of the pressure relief valve, the valve opens proportionally to discharge steam until the pressure level’s kPa (Kilopascals) returns to safe operating levels. This spring-operated valve ensures that the pressure in the system is always within safe operating levels and avoids rupture of the boiler drum.

It is important to determine why your pressure relief valve is open as there are two main reasons for steam release: the system’s pressure is too high or the valve needs to be repaired.

Situation 1: The boiler pressure gauge reveals the pressure is too high

If you note that the pressure relief valve is discharging pressure, it’s integral to look at the pressure levels of the system. The steam boiler’s pressure gauge is often located on the side of the boiler and can be indicated on HMI, so be sure to check if the pressure is within safe levels of operation. Depending on the age of your steam boiler model this could be within 75 to 100 kPA. If the levels are too high and the pressure relief valve is open, then the valve is performing as required and reducing the pressure within the system to safe levels. If the boiler’s pressure often climbs to higher-than-expected levels, it is important to get the system evaluated by a professional.

However, if the pressure gauge reads that the steam boiler is within or under the maximum pressure levels, then this could be a sign of an issue within the pressure relief valve or the steam boiler system.

Situation 2: The boiler will not reach optimal pressure or the leak is constant

If you notice the pressure within the steam boiler is not increasing or dropping unexpectedly, it’s important to check the pressure relief valve. If the gauge of the pressure relief valve reads little to no pressure, it could be an issue of an ill-fitting valve that requires replacement. Whether it’s a simple misalignment or a broken spring, a malfunctioning pressure relief valve should halt production immediately to protect the safety of the boiler operator.

If the pressure levels are dropping but steam is not escaping from the pressure relief valve or drain, there could be a leak elsewhere within the boiler. When suspected leaks are detected, it’s important to stop operating the steam boiler until it has been repaired and tested following your company’s steam boiler safety protocols.

Still uncertain about the safety of your pressure relief valve?

If the pressure relief valve doesn’t seem to be performing as required, it may be time to organise a replacement from an expert maintenance provider. Over time, sediment from steam can build up within the valve, leading to clogs or warpage that prevents it from sealing or maintaining pressure causing continuous steam leakage. Leaks will prevent the boiler from reaching the desired pressure, so it is important to adhere to a strict maintenance schedule and routinely check for wear and tear in your industrial steam boiler.

Regulations require that all Safety Valves fitted to Steam Boilers have a NATA Certified testing and tagging – Tomlinson Energy Service offer this service through Valve OSR in our South Australian Branch and can arrange this service throughout Australia.

Is your industrial steam boiler in need of maintenance?

Tomlinson Energy Service has provided premium industrial and commercial boilers and repairs to Australia for over 100 years. Our expert team are available for all your boiler service needs with 24/7 boiler and gas burner maintenance and repair. If your steam boiler has not been performing optimally or needs replacement parts, our knowledgeable and friendly specialists are here to help.

If you would like to get in touch with our team today, then please call us on +61 3 8560 0419 or fill out the contact form below.