Author: Multi Mode

Understanding the Different Types of Steam Boilers Used in Australia sadsad

Posted on by Multi Mode

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.

What is the Role of Steam Boilers in Australia’s Manufacturing Industries? sadsad

Posted on by Multi Mode

Steam boilers have helped to power the manufacturing industries not only in Australia, but across the world, for hundreds of years. Within manufacturing, steam boilers can play a varied, but vital role. From food processing to chemical production, steam boilers are responsible for many functions in the manufacturing sector, including the powering of machinery, for example. Keep reading to find out the role and significance of steam boilers in the manufacturing industry in Australia, and then find out where to go if you need professional steam boiler maintenance in Melbourne.

1: Energy for Mechanical and Thermal Processes

When it comes to manufacturing and energy, steam boilers provide two functions. First, they are capable of providing mechanical energy that can power machinery and drive turbines. Further, many industries within the manufacturing sector utilise steam for process heating. The controlled release of latent heat from steam actually allows for precise temperature control, which makes it essential for things like pasteurisation, drying and distillation. Steam boilers provide essential energy for many varied manufacturing processes, from powering conveyer belts to maintaining temperature within vessels or reactors.

2: The Food Processing and Beverage Industries

Steam boilers also play a critical role in the food and beverage sector of the manufacturing industry. Within this sector, steam boilers perform a number of essential functions. From blanching processes to sterilisation, steam is important for the production of food and beverage products. Steam is particularly important within the dairy sector, for example, in which pasteurisation is so critical. Another area is bakeries, which utilise steam boilers for the preparation of dough for baked goods. In addition, the food and beverage sectors require rigorous sterilisation and cleaning processes, for which dry steam is used in many cases. This makes steam boilers a critical part of the essential sanitation procedures that maintain the stringent food and beverage safety standards in Australia.

3: Pharmaceutical and Healthcare Industries

This sector also relies on steam boilers which provide the required thermal energy to assist with not only sterilisation, but also with the production of drugs too. When it does come to sterilisation, steam boilers again play a hugely important role in ensuring that equipment like autoclaves and things like surgical tools can be cleaned hygienically and then stored afterward. The use of steam boilers is critical within the pharmaceutical and healthcare sector.

4: The Textile Industry

Steam boilers are also utilised during different elements of production within the textile industry. Steam plays an essential role in important textile processes such as dyeing and printing. Steam boilers are also used in finishing processes, which need precise and accurate pressure and temperature control. Textile manufacturing workshops also require a stable and reliable source of heating, humidification, and energy in order to function safely and efficiently, and steam boilers play a critical role in achieving this.

5: Chemical Manufacturing

Steam boilers are important within the chemical manufacturing sector, as they help to provide the necessary heat for distillation, chemical reactions, and various synthetic processes. In addition, another benefit that steam boilers provide for this industry is to facilitate the creation of a variety of chemical products through providing steam, as well as heat energy. The chemical manufacturing process is a complex one which demands precise conditions, such as accurately high or controlled temperatures, and steam boilers are also important for this.

6: The Paper Industry

This is a sector that the mind may not be drawn to very often, however, steam boilers and the paper and pulp sector are closely related. Steam boilers are used in this industry for a variety of tasks, one of which is the heating and drying of wood fibres. During the intricate process of making paper, steam is applied to large cylinders in order to heat them, so that wet paper sheets may be passed between them. This ensures that the moisture evaporates, and that dry and flat pieces of paper are left behind. What produces this essential steam? Steam boilers. Further, these boilers are also used to power turbines which generate electricity for workshops and factories, and to produce steam for heating processes.

Do You Need Professional Steam Boiler Maintenance?

When it comes to steam boiler expertise, you don’t have to look any further than Tomlinson Energy Service. Backed by over 100 years of engineering and service experience, we know and understand the critical importance of maintaining your steam boiler, regardless of your industry. We are proud to be able to provide you with unparalleled experience not only in maintenance, but also in steam boiler installation and repair. In addition, if you need to purchase a steam boiler, or related thermal energy equipment, then you are in the right place. Plus, as a member of the Environmental Group Limited (EGL), you can be assured that we are also committed to the protection of the environment.

If 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.

5 Safety Guidelines for Operating Steam Boilers sadsad

Posted on by Multi Mode

Steam boilers play an important role in many different industries across Australia. They provide efficient heat and power in various settings, but it is critical to note that the operation of steam boilers requires knowledge of and adherence to strict safety guidelines. This helps to ensure that all boiler operators are safe, and that your boiler works effectively and efficiently. Keep reading to find out our tips for safe boiler operation, from proper training of operators to regular steam boiler maintenance. Whether you are new to the world of steam boilers, a boiler operator, or a seasoned steam boiler professional, these tips will help to ensure that you can maintain boiler safety.

Proper Training and Certification

This is the first step when it comes to the safe operation of boiler systems. It is essential in Australia that all steam boiler operators have the necessary training and certification required to carry out their role. These training programs are rigorous and comprehensive, and that is because the safe operation of steam boilers is a serious matter. Effective training will include steam boiler operation and maintenance, as well as safety procedures and emergency readiness protocols. When boiler operators are certified and trained, this ensures a standard of competency and an awareness of the hazards that come with boiler operation.

Water Quality and Treatment

Boiler efficiency and safety relies, in part, on proper water treatment. Water that is used in steam boilers must meet specific quality standards to ensure the proper operation of the boiler. To prevent corrosion and scale formation within the steam boiler, it is crucial that you have an effective water treatment program. This program will test for dissolved solids, pH levels, the conductivity of the water, as well as other water quality parameters. Checking and testing for these components will help to prolong the lifespan and quality of your boiler, and assist in preventing boiler failures.

Adequate Ventilation and Combustion Air Supply

It is essential that steam boilers have adequate ventilation in order to operate safely. When ventilation is insufficient, this can have very serious consequences, including a build-up of toxic gases like carbon monoxide. This is why it is critical that boiler rooms are properly ventilated. Further, it is also essential that boilers have an adequate supply of combustion air so that they can operate in a safe manner. This means that boilers need a supply of oxygen in order to burn fuel, and a lack of combustion air can result in the release of harmful pollutants that come from incomplete combustion. To help prevent this, you must ensure that combustion air openings are always clear of obstructions. In order to make sure that your steam boiler systems are in safe working order, carry out regular inspections to check the ventilation systems and air openings.

Be Prepared for Emergencies

It is critical that any boiler operator be prepared for potential emergencies. Operating and being around boilers comes with certain safety hazards that must be taken into account at all times. You must have an emergency plan in place which outlines the steps to carry out in case of emergency like fire, or boiler malfunction. You need to be prepared for the potential of these hazardous events, which means having emergency shutdown procedures in place, being in possession of fire suppression equipment, and having clearly communicated and easily accessible evacuation routes. You can enhance emergency preparedness by carrying out drills and training exercises on a regular basis that allow boiler operators to be familiar with emergency procedures. This in turn will help to make sure that in a real emergency situation, responses will be fast, effective, and efficient.

Regular Maintenance

Maintenance is one of the most important factors when it comes to the safe operation of steam boilers. Further to that, the key to maintenance for safety is the regularity with which it is carried out. Regular boiler maintenance is so important for ensuring boiler safety because regular inspection can pick up on any potential issues, or any operational problems. This means that if issues are identified, they can be repaired or rectified before anything goes seriously wrong. When it comes to maintenance, it is critical that you consult and work with experts in the boiler maintenance field. When you do so, you can rest assured that they have the knowledge, training, and expertise necessary to properly maintain your steam boiler.

Do You Need Steam Boiler Maintenance?

Here at Tomlinson Energy Service, we are here to help with all your steam boiler maintenance needs. Backed by over 100 years of engineering and service experience, we are proud to provide you with unparalleled expertise in installing, maintaining, and repairing boilers. Plus, as a member of the Environmental Group Limited (EGL), you can be assured that we are proudly committed to the protection of the environment.

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

Factors to consider when sizing a commercial boiler sadsad

Posted on by Multi Mode

Efficient heating is crucial for commercial spaces, and selecting the right-sized commercial boiler is essential for optimal performance, energy efficiency, and cost-effectiveness. Sizing a commercial boiler can be a complex process that requires a thorough understanding of various factors, such as heating load, system efficiency and space constraints. Let’s delve into the world of boiler sizing and discover the essential considerations for a successful heating system implementation.

Understanding the Heat Load of a Commercial Boiler

Properly sizing a boiler is essential for efficient and reliable heating in your commercial space. It all begins with a thorough understanding of the heating load of the building, or the operation you are using the boiler for. The heating load represents the precise amount of heat required to achieve your desired results. Factors such as the size of the commercial space, insulation levels, and the prevailing climate all contribute to the heating load.

Accurate calculations of the heat load ensure that you select a commercial boiler that matches the heating demands effectively, neither oversized nor undersized. Oversized boilers lead to wasted energy and inefficient operation, while undersized boilers struggle to meet the heating requirements, resulting in discomfort and excessive wear on the system. By accurately assessing the heating load, you can make an informed decision and choose a properly sized commercial boiler that optimises energy efficiency and ensures reliable heating performance for your commercial space.

Commercial Boiler efficiency ratings

When sizing a commercial boiler, it’s crucial to consider the efficiency ratings of different models. Boiler efficiency refers to how effectively the unit converts fuel into heat. These ratings represent the percentage of fuel energy that the boiler can convert into usable heat. Opting for a high-efficiency boiler ensures optimal energy utilisation and long-term cost-effectiveness. By selecting a more efficient boiler, you can significantly reduce operating expenses and minimise environmental impact through reduced fuel consumption. When comparing boiler options, consider the specific efficiency requirements of your commercial space and choose a model that aligns with your heating demands while maximising energy efficiency.

Space Constraints & Installation Considerations

When sizing a commercial boiler, careful assessment of available space and consideration of installation factors are crucial. With limited space in commercial buildings, it’s essential to choose a boiler system that fits within the designated area. Compact or modular commercial boilers are specifically designed to address space constraints while maintaining performance. Additionally, it’s important to account for ventilation requirements and accessibility for maintenance, ensuring proper operation and compliance with safety regulations. Consulting with a qualified boiler professional can help identify the most suitable installation location and address potential challenges. By considering space constraints and installation considerations, you can seamlessly integrate the commercial boiler into your building.

Load Diversity & Future Expansion

Considering load diversity and future expansion is crucial. Commercial spaces often have varying heating demands due to different zones, peak periods, or changing occupancy. It’s essential to account for these diversities to ensure the selected commercial boiler can effectively meet fluctuating heating requirements. Additionally, anticipating future expansion plans or changes in the building’s heating needs is vital. By selecting a boiler system with adequate capacity and flexibility, you can accommodate growth without the need for significant upgrades or replacements. Planning for load diversity and future expansion ensures the long-term efficiency and reliability of the boiler system, providing optimal heating performance and comfort for your evolving business needs.

Maintenance and Service Requirements

When sizing a commercial boiler, considering the maintenance and service requirements is crucial for its long-term performance and reliability. Regular maintenance is necessary to keep the boiler operating efficiently and prevent potential issues. Prioritising proper boiler maintenance and timely servicing from an expert such as a member of the team at Tomlinson energy, extends the lifespan of the boiler, maintains optimal energy efficiency, and prevents costly breakdowns. By considering the maintenance and service requirements of the commercial boiler, you can ensure its continued performance and maximise the return on investment for your heating system.

Commercial Boiler repair, maintenance, and installation:

It is essential to have any commercial boilers installed and maintained by a qualified industry professional. At Tomlinson Energy, we offer 24/7 boiler and gas burner maintenance and repair services to ensure your workplace is operating at full capacity, always.

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

Four signs that you may require boiler repair sadsad

Posted on by Multi Mode

Boilers are essential for the function of many industries, from food production to sterilisation and even paper production. You can expect to get on average 20-30 years of lifespan from a steam-powered boiler with good care and maintenance. But even the most reliable boilers can experience problems and breakdowns over time, causing inconvenience, financial burden, loss of revenue, safety hazards, and shutdown of operations. That’s why it’s crucial to be aware of the signs that you may require boiler repair, so you can act promptly and avoid costly issues down the road.

In this article, we will take a closer look at some of the most common boiler problems and their symptoms. Australian Standards AS2593 has a requirement for all steam boilers regardless of size to have regular service and safety checks. This involves a combination of in-house reviews from facility workers and external reviews from boiler specialists. If any problems are highlighted upon inspection, they should immediately be reported to a service technician to prevent any further issues.

Signs you need boiler repair

#1 – Strange Noises

Is your workplace boiler making strange or loud noises? While some sounds, like humming or clicking, are normal during operation, persistent strange noises such as water hammering, may indicate a problem. Banging, clanking, whistling, or gurgling sounds can signal issues like air in the system, rapid pressure changes, steam disruption, low water pressure, or incorrectly installed valves. If left unaddressed, these issues can lead to further damage and increase the risk of breakdowns. A trained technician can identify the cause of the noises and recommend the necessary boiler repair or maintenance to keep your boiler running smoothly and safely. Ignoring strange noises can result in costly repairs or even safety hazards.

#2 – Leaks and Drips

Leaks and drips around your boiler can indicate underlying issues that require prompt attention. Common causes of water leaks include a broken or damaged pump, corrosion, or a malfunctioning valve. Ignoring these leaks can lead to low pressure or even system failure. Drips may not always be immediately visible and may occur within air vent shafts. Gas leaks pose a more serious safety hazard and should be addressed immediately by a licensed professional. Workplaces should be upholding the highest safety standards, with gas detection systems to keep workers safe in case of any leaks. To ensure the safety and proper operation of your boiler, it’s essential to have a licensed boiler repair professional inspect and fix any leaks or drips as soon as possible.

#3 – Irregular Heating

If heat is being dispersed at irregular intervals or inconsistently across a space, it could be a sign that your boiler needs repair. Irregular heating can be caused by heat escaping the system due to inconsistent insulation, poor installation, or components working incorrectly. If these issues are not addressed promptly, they can lead to higher energy bills and increase the risk of chain reaction problems – in industrial settings, this may include inadequate sterilisation or incorrect product temperatures. It’s essential to act fast when you notice any irregular heating to avoid further problems.

#4 – Increased Energy Bills

If your business or workplace notices a sudden increase in your energy bills, it may be a sign that your boiler is not functioning efficiently. Inefficient boilers use more energy to provide the same level of heating, leading to higher energy costs. If left unchecked, it may lead to the point where the cost of repair is dwarfed by the increased cost of energy bills, especially given the large output of industrial-grade equipment. A combination of regular staff inspection and external maintenance audits can help prevent energy waste and ensure that your heating system operates efficiently with timely boiler repair.  

Boiler repair, maintenance, and installation:

It is essential to have any boilers installed and maintained by a qualified industry professional. At Tomlinson Energy, we offer 24/7 boiler and gas burner maintenance and repair services to ensure you are living and working in a comfortable and safe environment. Alongside our boiler repair services, our expert team also offers industrial steam boiler and burner installation services so you can ensure efficient operation, always.

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

Boilers and carbon monoxide poisoning – safety tips sadsad

Posted on by Multi Mode

Boilers can produce carbon monoxide (CO) if they are not properly installed, maintained, or vented. Carbon monoxide is a colourless, odourless, and tasteless gas that is toxic and can be deadly if inhaled in high concentrations. CO is produced when fuels such as gas, oil, or coal are burned incompletely, due to insufficient oxygen supply or incomplete combustion.

Boilers and Carbon Monoxide

Boilers can produce CO if the burners are not adjusted properly or if the heat exchanger is cracked/ damaged. This can allow combustion gases to escape into the living space. This is why it is important to have your boiler inspected and maintained by a qualified professional on a regular basis. Additionally, it is important to have carbon monoxide detectors installed in your home and workplace to alert you if there are dangerous levels of CO present.

In Australian household environments, the leading cause of carbon monoxide poisoning is old, faulty gas heaters. Most Australian households do not use indoor boilers for room heating, instead opting for ducted heating or gas heating systems for climate control. However, boilers are common for hot water systems; but are usually placed outdoors to improve ventilation. Additionally, many workplaces use industrial-grade steam boilers due to their large rapid heating capacity. These require regular maintenance by a boiler installation professional. 

Carbon Monoxide in the workplace

SafeWork NSW notes the most risk industries for workplace carbon monoxide poisoning at work are ones that involve the ‘burning of compounds containing carbon’ whilst working in an ‘enclosed or restricted space.’ These industries include: ‘cooks, blast furnace and boiler room workers, diesel engine operators, garage mechanics, brewery workers, pulp and paper workers, firefighters, glass manufacturers and coal miners.” Workers in these industries should remain alert and ensure all work safe practices are being followed to prevent hazards.

Why is carbon monoxide dangerous?

The colourless and odourless characteristics of carbon monoxide make it difficult to detect without special monitoring equipment, increasing the danger profile of the gas. Often people don’t realise that they are suffering from carbon monoxide poisoning until the onset of symptoms has occurred.

Carbon monoxide binds to haemoglobin in the bloodstream, reducing the amount of oxygen that can be transported to the body’s tissues. Even low levels of CO can cause symptoms such as headaches, nausea, dizziness, and weakness. In higher concentrations, CO can cause unconsciousness, brain damage, and even death.

CO is a serious health hazard, and it is important to take steps to prevent exposure. This includes properly maintaining fuel-burning appliances, ensuring proper ventilation in enclosed spaces, and installing carbon monoxide detectors in your home or workplace.

How to protect against carbon monoxide

To protect yourself from carbon monoxide poisoning, it is important to take the following steps:

  • Have your boiler inspected and maintained regularly by a qualified professional. This includes checking the ventilation system, heat exchanger, and burner to ensure they are working properly.
  • Install a carbon monoxide detector in your home and workplace. This will alert you if there are dangerous levels of CO present.
  • Ensure proper ventilation in the boiler room if it is located indoors. Keep vents clear of debris and maintain strong ventilation.
  • Never use a gas stove, oven, or grill to heat your home, and never use a portable generator inside your home or garage.
  • If you suspect that you or someone else may be experiencing carbon monoxide poisoning; leave the property, take steps to ventilate the area by opening doors and windows if possible, and seek medical attention immediately. Call emergency services (000) in Australia.

Other sources of Carbon Monoxide within the home

Carbon monoxide poisoning most commonly occurs from faulty and leaky gas appliances, heaters, power generators and barbecues. In Australia, LPG appliances and heaters add a pungent chemical called Ethyl Mercaptan to ensure users can distinctly smell leaking gas. This is because LPG is naturally odourless. However, CO does not include this chemical addition. Carbon monoxide leaks can be impossible to detect within a home without a detection system or the onset of symptoms.

Maintenance, installation, and repair of boilers:

To protect your household and workplace from carbon monoxide poisoning, it is essential to have any boilers installed and maintained by a qualified industry professional. At Tomlinson Energy, we offer 24/7 boiler and gas burner maintenance and repair services. Maintain a safe work and living environment, access to heat and efficient workplace operation.

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

Common Steam Distribution Problems in Steam Boilers and How to Fix Them sadsad

Posted on by Multi Mode

What is steam distribution in steam boilers?

Steam distribution refers to the process of delivering steam from the steam boilers to the various points of use in a system. In a typical steam boiler system, steam is generated in the boiler and then flows through a network of pipes to the points where it is needed, such as heating systems, process equipment, or turbines. Steam distribution systems can be of various sizes. Individual household systems may connect the boiler to a few key rooms such as the kitchen and bathroom, meanwhile, industrial-grade boilers can include far more advanced systems to provide steam throughout hundreds of rooms around a facility, such as a hospital, restaurant complex or factory.

The steam distribution system is an essential component of the overall steam system, and it is critical that steam is distributed evenly and efficiently to ensure maximum energy efficiency and maintenance of the desired steam pressure and temperature throughout the system.

A well-designed steam distribution system should consider factors such as the size and layout of the facility, the steam load variability requirements, and the operating conditions of the equipment being served. Proper pipe sizing, insulation, and valve selection are all critical components of a well-functioning steam distribution system.

However, steam distribution can be prone to several problems, which can compromise the performance of steam boilers.

Condensate build-up

Condensate build-up refers to the accumulation of liquid condensate in a steam boiler system. When the steam comes into contact with colder surfaces, it can condense back into the water, releasing heat in the process and reducing operative efficiency. Condensate can accumulate in low points of steam pipes, causing reduced steam flow and potential blockages. This can result in poor heat transfer, increased energy consumption, and decreased boiler efficiency.

Steam leakage

Steam leakage is another common steam distribution problem that can lead to a loss of energy and reduced boiler efficiency. Steam leakage can occur due to faulty steam valves, damaged steam pipes, or improper installation of steam distribution systems.

Uneven steam distribution

Uneven steam distribution can be caused by several factors, such as blockages or obstructions in the steam pipes, improperly sized pipes, or incorrect valve settings. The result is that some areas of the boiler or steam system will receive more steam than they need, while others will receive less. This can lead to inefficient operation, reduced steam quality and performance, increased wear and tear on the system, and potential safety hazards.

To fix this problem, the source must be identified. This may involve checking the steam pipes for blockages or damage, reviewing the pipe sizing and valve settings, and evaluating the overall steam system design. Once the source of the problem is identified, solutions may include adjusting valve settings, replacing damaged or undersized pipes, or installing additional piping to balance steam distribution.

Water hammer

Water hammer is a term used to describe a phenomenon that occurs when a sudden pressure change causes a rapid movement of fluid, creating a loud banging or hammering sound. In a steam system, water hammer occurs when steam and condensate are flowing in the same pipe, and a valve is suddenly closed, causing the momentum of the fluid to create a pressure surge that can cause pipes to vibrate, bang or even rupture. Incorrect valve sizing improperly installed steam traps, or incorrect system design can all lead to water hammering.

Corrosion

Corrosion is a common problem in steam distribution systems that can result in reduced boiler efficiency and increased energy consumption. This problem can occur from exposure to moisture, high temperatures, and chemical reactions. Corrosion-resistant materials should be used in steam boilers and distribution systems to avoid this issue occurring.

How to fix these steam boiler issues? 

The best way to fix most of these issues is by regular steam boiler and distribution system maintenance checks. Regular check-ups, cleaning of pipes, and installation and maintenance of steam traps are all essential parts of ensuring an optimally operating steam distribution system. Regular inspections can also help identify and prevent any leaks, blockages, or damage that has occurred to the pipe system, alongside any improperly installed infrastructure. Further solutions may involve adjusting valve settings and replacing incorrectly sized or faulty pipes.

Inefficient steam distribution can lead to exaggerated steam boiler operation costs. While it may seem expensive to fix the issue, the cost of inefficiency over time may balloon to be much greater if not resolved early.

Does your business need steam boiler experts?

Look no further than Tomlinson Energy Service. We maintain, repair, and install boilers whilst providing specialised and professional customer service. We are proud to offer you over 100 years of engineering and service expertise. In addition, as a member of the Environmental Group Limited (EGL), we are proudly committed to the preservation and protection of the environment.

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

4 Uses of Dry Steam in Industrial Applications sadsad

Posted on by Multi Mode

When it comes to boilers, dry steam is used for many applications. This is due to the natural benefits of dry steam, which will be detailed in this article. First, you might be wondering what is meant by the term, dry steam. This term is used to describe steam that does not contain water particles, meaning that the moisture content of the steam is very low. This is where dry steam gets its name. The dryness of steam directly affects the amount of transferable energy that is in the steam. This in turn affects the quality of heating produced by a steam boiler. The use of dry steam is preferable for many applications and uses, including in improving steam boiler lifespan, and in the food processing industry. Keep reading to find out all about the benefits and uses of dry steam, and then to find out where to go for professional boiler services in Melbourne.

Dry Steam in Food Processing and Production

Dry steam is used in the food processing and production industry because of its many benefits. As we have explored, dry steam is able to transmit heat energy very efficiently, and the vapour is also able to flow/travel through cracks and crevices without trouble. There are therefore many benefits to using dry steam for sanitation and sterilisation in the food processing industry, including that it is highly efficient in killing bacteria, and that it leaves surfaces dry and ready for use.  Other advantages of dry steam include:

  • Environmental benefits: The use of dry steam means that water is not used to wipe down and clean surfaces, machinery, and equipment, which is a better cleaning process for our environment
  • Cleaning and sterilisation benefits: not only does dry steam disinfect and kill bacteria and other microorganisms, but it also has the ability to dissolve food and beverage residue, such as oils

Another important benefit of using dry steam in food processing and food production is that this steam has the potential to improve the quality of the finished product and ensure that it is safe for consumption. For instance, in fresh products that need to be dried, dry steam is used to ensure that harmful organisms are killed and that the product retains freshness, flavour, and colour.

Steam Purity and Dry Steam in Sterilisation Processes

Sterilisation is a critical feature of many important organisations such as hospitals and laboratories, which rely on these practices to safely function. Once again, dry steam is used in many cases for this because of its ability to completely sterilise surfaces and equipment safely and efficiently. In contrast, if wet steam is used in sterilisation processes, surplus water or moisture can settle on surfaces, can cause corrosion, and can prevent proper sterilisation. Hence, dry steam is not only preferable for sterilisation, but can be critically important in many instances.

Dry Steam and Boiler Lifespan

Dry steam is preferable for use in steam boilers because it can actually help to extend the lifespan of the boiler. When there is moisture present in steam, over time, this moisture can cause corrosion of valves and fittings. Because the moisture is transferred through wet steam at high velocities, this can increase erosion of boiler parts. It is also notable that moisture in steam is capable of transmitting impurities, and this is what can cause scaling within boiler pipes. This is why the use of dry steam is preferable over wet steam, as it has the capacity to extend the lifespan of boilers.

Dry Steam and Paper Production

Paper production is still such an important process even in the 21st century. The process of manufacturing paper is a complex one that involves water, chemicals, energy, and cellulose that is extracted from the wood chips that paper is made of. Steam actually plays a large role in the production of paper, and dry steam is once again, preferable in this process over wet steam. In the process of making paper, one of the steps is drying the paper, which is done by pressing it through rollers steam-heated rollers. The rollers should be heated by dry steam in order to ensure that the moisture content of the finished paper does not go above the required levels. Paper that has a higher moisture content than allowable will be of a lesser quality than is desirable.

Do You Need Steam Boiler Experts?

Look no further than Tomlinson Energy Service. We maintain, repair, and install boilers whilst providing specialised and professional customer service. We are proud to offer you over 100 years of engineering and service expertise. In addition, as a member of the Environmental Group Limited (EGL), we are proudly committed to the preservation and protection of the environment.

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

How Can I Extend the Life of a Steam Boiler? sadsad

Posted on by Multi Mode

Steam boilers are integral to many industries, and they have played a role in industrialisation since the times of industrial revolution. When your business or industry relies on boilers for heating, steam production, or another function, it’s important to have the information about how to get the most out of the lifespan of your boiler system. There are certain steps to take that can help to make the most and even potentially extend the life of your boiler, which is why we have put together this list of handy tips. Keep reading to find out all about the useful hints and tricks we have on how to get the most out of your steam boiler.

How Long Should a Boiler Last?

On average, you can expect to get 20 to 30 years of life and operation out of a steam-powered boiler. That being said, this varies depending on the application of your boiler, the particular setting it operates in, and the industry it is used in. If you follow the maintenance guidelines, and some of the tips in this article, you have a good chance of getting the most out of that average life expectancy mentioned above. Of course, ensuring that the proper safety and repair protocols are followed is essential if you hope to get decades out of your boiler.

Regular Maintenance

A cornerstone of extending the lifespan of a steam boiler is regular maintenance. This is true of any piece of machinery, or indeed, of anything that one values. If you wish to keep it spick and span, in good working order, safe, and extend its lifespan, then keeping up with maintenance is essential.

As mentioned, regular assessment and maintenance by a professional in boiler systems are also imperative to the safe functioning of the system, and the safety of those people who come into contact with it or are around it daily. This is one important reason for regularly scheduled maintenance, and another is that these check-ups can identify problems or concerns that may then be fixed before they turn into big issues for the system. This early intervention is then what can help to extend the steam boiler’s lifespan.

Check Water Quality

The quality of the water inside your boiler actually plays a large role in the quality of the operation of the boiler system. When hard water is used within the system, it leaves behind mineral deposits or scales during the process of conversion to steam. This build-up creates issues with the boiler working as it should, and can cause it to work overtime to compensate, putting pressure on the whole system.

You can mitigate the risk of mineral build-up and the accompanying safety risks that come with it, by installing or using a water softener as part of the boiler system. Check out this Wikipedia page for more information all about boilers, and then discover even more with 4 facts about steam boilers.

Know When to Replace

There are many considerations when it comes to steam-powered boilers, but one important one is knowing when it’s time to maintain and repair, and when it’s actually time to replace. This is a particularly important thing to consider when it comes to ensuring and maintaining the safety of your boiler system because boilers that need replacing can exhibit unsafe characteristics.

When it comes to knowing when a boiler might be coming to the end of its life, or you may be approaching the appropriate time for a replacement, there are several things to look out for:

Strange Noises: Unusual or irregular noises can indicate that something is wrong with your boiler, or that it could be approaching a breakdown. For example, banging noises, whistling noises, or gurgling sounds could be a sign that it’s time to have your boiler system assessed by a professional.

Loss of Pressure: If your boiler is regularly losing pressure, then this can also be a sign of an impending breakdown. Loss of pressure could be caused by a number of things, such as damage to the boiler pump, or damage to the pressure relief valve. It’s important to remember that if you do suspect something is wrong with your boiler, or that it is failing, you must consult a professional to have it inspected.

Do You Need Experts in Steam Boilers?

Here at Tomlinson Energy Service, we are proud to offer you more than 100 years of engineering and service experience. We provide unparalleled expertise in maintaining, repairing, and installing steam boilers, as well as other thermal energy system-related services. We provide exceptional customer service and a seamless customer experience. Plus, as a member of the Environmental Group Limited (EGL), we are proudly committed to the protection of the environment.

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

History of the steam boiler sadsad

Posted on by Multi Mode

Steam boilers have become an essential household item since their invention. They played a pivotal role in the industrial revolution, bringing the western world into the modern technological age. Steam engines have been experimented with or proposed in some capacity for centuries. The first recorded – ‘the Aeolipile’ – was mentioned by Vitruvius in 1st century Roman Egypt. However, steam boilers became more recognised in the 17-1800s with the invention of the kettle boiler. These simply involved placing water above a firebox, allowing it to boil into steam. Since then, boilers have had various iterations over the decades and centuries to improve efficiency and application. 

Denis Papin and the pressure cooker 

In 1679, French scientist Denis Papin designed the first pressure cooker. He organised a system that placed a sealed pot above a high heat source. Papin is credited with introducing valves to steam boilers to allow them to release pressure before systems become unsafe.  

Flooded Mines and Industrial Pumps

Throughout the late 1600s and 1700s, Europe was experiencing a coal mining boom. However, during this time, mining was completed by pickaxes, and transport of goods was achieved by pulley and minecart. The mines were often flooded when water veins were found or it rained, and it proved difficult to get the water out with hand labour. Various iterations of steam engines were patented during this time, beginning with Jeronimo de Ayanz’s machine that propelled water out of the mines using steam in 1606. Followed by Thomas Savery’s steam-powered pump in 1698. Savery’s machine had significant faults: safety concerns, a lack of durability, wasted energy potential and a requirement for operation, installation, and maintenance within the dark and potentially flooded mine. The machine also had a maximum height capability of 10m of pumping, not feasible when many of the mines travelled far deeper than this.

The Newcomen Engine – an early boiler

Due to the faults presented by Savery’s design, Thomas Newcomen invented the Newcomen engine. This design used atmospheric-level steam pressure (as opposed to requiring accumulated steam pressure). Newcomen’s design was very popular throughout 1700s Europe as it was more efficient than the alternatives, but still had issues. It constantly required cold and hot water to cool and heat the steam cylinder. However, this design eliminated the requirement for horse-operated pumps – a feature of Savery’s machine – drastically reducing operating costs.  

Boilers and the industrial revolution

Over the course of the industrial revolution, steam engines and boilers underwent multiple iterations and improvements attempting to solve some of the problems presented by earlier models. This included maintaining temperature and improving the pressure capabilities of the vessels. A notable example is the James Watt steam engine, which added a separate condenser unit to previous steam pump iterations. Steam engines became an essential part of the industrial revolution as they were used for powering trains, carts, factories, mills, and breweries.

Babcock & Wilcox Company – a modern boiler 

The first modern recognisable steam boiler design was patented by George Babcock and Steven Wilcox in 1867. This design has been described as the first ‘convection boiler’ and utilised tubes inside a firebrick-walled box. However, the initial designs were very small in size and capacity. Meanwhile, a different business, the Stirling Boiler Company, founded in 1891, began making larger industrial boilers labelled the ‘H-type.’ In 1907, the two companies merged to create the ‘H-type Stirling boiler’, a combination of the two designs that were large and incredibly popular.   

Since this inception, boilers have continued to increase in size, capacity, and efficiency. By the 1950s and 60s, boiler designs could generate 9,000,000 pounds of steam, (1,300 megawatts of electricity per hour,) compared to the H-type Stirling’s 50,000 pounds of steam. Modern-day boilers are used within a wide variety of industries for various applications.

Tomlinson Energy – 130 years of steam boilers. 

That’s right. Tomlinson Energy has over 130 years of experience delivering steam boiler services to a wide variety of industries. We specialise in the sale of high-quality steam boilers from world-renowned brands, as well as the maintenance of a wide catalogue of boiler types. Tomlinson Energy has been there to witness the improvement of boiler technology over the company’s lifespan and remains on the cutting edge of the market.  

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.