Depending on the industry, you may have to choose between a fire tube or a water tube boiler. These two steam boilers both have their benefits but will provide better results for particular industries. Our specialist boiler sales team will be breaking down these two popular boiler types so you can have a better understanding of them, and what will best suit your operations.

Fire tube boilers

Sometimes referred to as shell boilers or drum boilers, fire-tube boilers are thought of as the more cost-effective steam boiler solution and are suitable for smaller industrial applications. With fire tube boilers, the burner produces gases that travel through small tubes in a pressurised cylindrical drum, or shell, surrounded by water; this creates the steam. Fire tube boilers can sometimes be distinguished by passes — the metric used to measure how many times the flue gas (combustion gas) passes through the pressure vessel, transferring heat to the water to create steam.

Wet and dry back

Fire tube boilers can be either wet or dry back. Wet back boilers have water-cooled combustion chambers, which increases the heat exchange surface and eliminates the need for the rear outer casing to be protected from excessive heat. Dry back boilers rely on refractory lining to increase the heat exchange surface.

 

Pressure rating

The pressure rating and maximum output of a fire tube boiler tend to be limited by the furnace thickness. The code states that the maximum furnace thickness cannot exceed 22 mm. This is one of the reasons that fire tube boilers are ideal for smaller industrial applications as their maximum pressure rating and output typically will not meet the demands for higher intensity applications.

 

Compact and flexible

Fire tube boilers are fairly small in terms of physical footprint and thus are available to purchase in package form making them easy to transport and install on-site. Additionally, this also makes them easier to relocate should the need arise. Their general cleaning and maintenance are easy to handle with simple, regular cleaning schedules and readily available replacement parts. If you require any assistance with your fire tube steam boiler maintenance, then get in touch with our boiler sales team today.

Water-tube boilers

The easiest way to understand a water tube boiler is to think of it as the opposite of a fire tube boiler. In this instance, water flows through the tubes and the hot combustion gases pass around the tubes, heating up the water. Water-tube boilers generally have multiple drums (or shells) compared to the single drum in a fire tube boiler, this also means they can be overall larger in size (but are also available in smaller sizes). A standard water tube boiler consists of multiple burners positioned on the wall in either vertical or horizontal firing configurations.

High-pressure steam boiler

Water-tube boilers tend to have higher maximum pressure outputs compared to fire tube varieties with capabilities of reaching as high as 5,000 psig. To compensate for the equivalent amount of stress but higher pressure levels, the tubes are smaller in diameter. The higher pressures and faster recovery rates of water tube boilers compared to fire tube boilers are a couple of the reasons why they are preferred in higher-output applications such as chemical processing and power generation stations.

 

Models for every application

As mentioned earlier, water tube boilers can be both large and small in design. The smaller models are available in packaged steam boiler form, making them easier to transport and install by our boiler service team. The larger designs, however, must be transported in separate parts (these would be boilers suitable for high-output industries) and assembled at the site — resulting in a longer install time.

 

High performance, High efficiency

Water-tube boilers are made for high performance, so it’s no surprise that their efficiency is made to match the high-output industries they’re made for. They’re so efficient that they can even be used to produce superheated steam (perfect for high-output energy generation applications) and saturated steam (ideal for heating applications).

Are you looking for a quality steam boiler?

Tomlinson Energy Service is Australia’s premium steam boiler manufacturer and supplier. We can deliver unparalleled products and services tailored specifically for your industry so you always know you’re getting the perfect fit for your operations.

Get in touch with our boiler sales team today by calling your state office or filling out our online contact form.

Blowdowns are an important part of industrial boilers and commercial boilers; a blowdown is the process of flushing water from the tank to mitigate and control the build-up of impurities. There are many things to consider when choosing a new boiler, but guaranteeing you have the correct blowdown vessel is key to ensuring a safe and unhindered steam boiler operation.

The basics of a blowdown

A blowdown is the intentional flushing of water from a steam boiler to remove any contaminants that may have built up over the course of its operation and control the level of totally dissolved solids (TDS). Contaminants include particles from any treatment chemicals, that, over time can form solid sludge at the bottom of the tank or remain suspended and will continue to grow if not “blown down”.

Blowdowns can be initiated automatically or manually (depending on the type of valve installed); their frequency depends on several factors including the size and type of boiler. Our boiler sales team know boilers inside out and will help to establish a manual blowdown schedule for you based on your specific boiler. As a rule of thumb, blowdown rates should be between 4% – 8% of the boiler’s feedwater flow rate.

Why do contaminants need to be blown down?

If allowed to remain in the boiler tank, the contaminants will affect the quality of the steam leading to reduced performance and pipe damage/corrosion. Steam boiler blowdown must be performed regularly to avoid corrosion; high contaminant levels will accelerate pipe corrosion which can become costly and require avoidable boiler maintenance services.

The blowdown vessel

When a blowdown occurs, it must be performed in a carefully controlled manner — this is what the blowdown vessel is for, a tank that shares physical similarities with a vertical compressed-air receiver. The blowdown process pipes down the expunged water into the vessel for depressurisation; it then vents off any flash steam and collects the condensed water and solids for cooling and disposal via the premises’ wastewater collection system.

Choosing the right blowdown vessel 

When working with our boiler sales team to select an industrial or commercial boiler they will be able to recommend an appropriate vessel for your unit. There are still some general aspects that should be considered, though.

• The blowdown vessel should be at least three times larger than the water blowdown volume; our sales team will advise on the largest blowdown your boiler will experience and choose the right vessel for you accordingly.
• The tank pressure and the pressure of the blowdown water as it leaves the tank should not exceed 35 kPa.
• Blowdown vessels should not be insulated as they’re meant to cool the water down; because of this, other safety protocols and measures should be considered such as guard rails and placing the vessel in an area where contact is less likely to be made.

Temperature control

As the boiler is in operation when blowdown is performed, the temperature of the water can be quite high. As a rule of thumb, the blowdown water should not exceed 71° C. This can become quite tricky in situations where the boiler water is evidently above this temperature. In these situations, our boiler sales team will recommend installing a cold-water injection system to cool the water as it leaves the tank and enters the vessel.

This is typically done by installing a direct-acting temperature control valve system, or a digital control system coupled to a solenoid valve. When a predetermined temperature is reached within the water mass, the control valve or solenoid valve will open, injecting cold water into the tank and ensuring it’s suitable enough to enter the blowdown vessel. Please note that a certified backflow prevention device will need to be installed should the cold water be sourced from a potable supply.

Are you looking for new industrial boilers in Australia?

Tomlinson Energy Service has been providing premium, first-class industrial and commercial boilers to Australia for over 100 years and is the country’s largest packaged boiler supplier. Our boiler sales team can provide you with optimal product recommendations including blowdown vessel fittings and operation 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 the contact form below.

As Australia’s leading boiler service specialists, we’ve had countless years of experience with installation, maintenance and professional advice. One of the crucial aspects to any boiler operation, an aspect that is often not given appropriate consideration, is the boiler room — the layout, the appliances and most importantly, the safety. Regardless of how good your boiler is and how much care you put into operating it, if your boiler room is not adequately equipped, then it could all be for naught. Our specialists have curated this list of six key considerations for the construction of a boiler room or the upgrade of an existing one to help you tackle the topic with confidence.

1.     Safety compliance

Before any work can be carried out in a boiler room, it must be first compliant with the relevant standards — such as: AS 3892 Pressure Equipment — Installation, AS 2593 Boilers — Safety Management and Supervision Systems, AS 5601 Gas Installations and AS 4041 Pressure Piping. Compliancy is vital to safe and proficient boiler operation. Give our experts a call to learn about all the appropriate standards, building codes and WorkSafe regulations that should be considered and complied with.

2.     Appropriate flooring

Appropriate flooring with a grip that can provide firm footing when wet and is also fire resistant is crucial for boiler safety and compliance. Accidents could be anything from explosions (which are rare but can happen if a boiler is not operated properly) to water bursting from gauges. Even minor incidents such as spilling liquids can lead to more serious incidents which is why the flooring must be sufficient, so it is ready for numerous situations. This also goes hand-in-hand with wearing proper PPE equipment such as boots with good grip.

3.     Proper ventilation

Ventilation is important and required when dealing with boilers, but gas boilers especially demand some further ventilation. AS 5601 will provide the relevant, detailed measurements when it comes to natural ventilation. In some cases, active ventilation such as force fans will also be required to pump air in from outdoor. Failing to provide proper ventilation can lead to light-headedness from the fumes (which can, in turn, influence operation proficiency) as well as the potential development of serious ailments from the prolonged exposure.

4.     Sufficient lighting

As with the aforementioned elements, lighting also has a direct impact on the safe operation of boilers. Inadequate lighting can cause eyestrain and headaches; boilers should be operated with a clear head and cognitive mind to mitigate mistakes. All gauges and controls must be legible from the proper operating position — if a technician has to use supplemental lighting to operate the machine, then more efficient lighting is required. This can particularly be an issue if you are sprucing up an older boiler room. Modern LED lights situated around the room and concentrated in key areas are a good place to start when illuminating your boiler room.

5.     Ample floor space

Operators moving throughout a boiler room should have clear paths and not have to worry about unnecessary obstructions, whether they’re attached features of the original building that have not been removed or loose items and tools that have not been stacked away properly. Be sure when designing a boiler room that an appropriate amount of clearance is considered around the boilers themselves for suitable operation — this will also make our repair and maintenance boiler service much simpler. In addition to various boiler services, our specialists can help you with the planning of your boiler room and are always on-hand if you’re unsure what the correct amount of clearance space should be.

6.     Suitable storage

There are many items, accessories and tools that will be needed at various times, so keeping them close at hand will help sustain an efficient operation. This is where suitable storage will come in. If possible, try to plan for in-built storage units to keep seamless and uninterrupted walls (as opposed to placing free-standing cabinets). Though free-standing cabinets will most likely have to be used in some areas, the fewer physical obstructions, the better. Try to consolidate all the tools in one area to avoid confusion, and place fire extinguishers and hoses in key points around the room so accidents can be promptly quelled.

Australia’s boiler service specialists

Tomlinson Energy Service stocks a range of packaged steam boiler systems, gas burners and hot water boilers as well as provide comprehensive 24/7 boiler maintenance services. Whether you need advice on structuring your new boiler room, are looking to outfit it with some new boilers or require some maintenance — Tomlinson are just a phone call away.

Contact us today by calling one of our state’s offices or filling out the online enquiry form below. One of our team members will be happy to help with all your boiler questions.

Historically speaking, steam boilers haven’t had the best track record with safety, but just as the modern era has seen the development of better steam boilers, so too has their safety record improved and, most importantly, the safety protocols and knowledge surrounding their operation. That being said, incidents do still happen, and the consequences can range from minor burns to more extreme cases such as explosions or fires. Today’s article is going to cover the etiquette surrounding steam boiler safety, including steam boiler maintenance — the most crucial factor of all.

1.     Wear proper PPE

It never hurts to state the obvious when it comes to industrial devices; one of the most common incidents associated with industrial steam boilers is related to burns from making contact with the hot exterior.  Before working with or in the proximity of steam boilers you should ensure you’re equipped with the appropriate PPE (Personal Protection Equipment) to mitigate this from occurring. Proper PPE includes:

• Safety glasses;
• Gloves;
• Long sleeve shirts;
• Appropriate safety boots and trousers; and
• Ear protection.

2.     Be aware of your surroundings

Falling is another commonly associated incident; the injuries can range from a minor scrape to more serious wounds. Rather than taking the chance, we recommend you implement a take five approach and never rush things when operating steam boilers or similar equipment. Be aware of your surroundings and ensure the encompassing area is kept clear of any unnecessary items on a daily basis. This is a good habit to get into and could circumvent the occurrence of incidents.

3.     Never operate unfamiliar devices

Given the nature of steam boilers, under no circumstances should they ever be operated by untrained or inexperienced hands. An operator should be familiar with every component of a boiler to ensure they are:

1. in as much control as possible in the event of an incident; and
2. can read the boiler and foresee, in-a-manner-of-speaking, when an issue may (component repairs, general maintenance etc.).

On-the-job training is not enough; formal sessions should be implemented to ensure the operator has a thorough understanding of the device — this includes simulated emergency drills to acclimatise the operator to thinking on their feet in case of a genuine emergency.

4.     Steam boiler maintenance

The most crucial action you can take to prevent incidents from occurring is following correct and regular steam boiler maintenance practices — this will mitigate the chance of components failing (which can, in some extreme cases, actually result in the boilers exploding).

It’s not just about repairing components when they begin to degrade, but ongoing preventative maintenance to ensure your boiler is in optimal working condition — this will result in a more efficient system overall. You can contact Tomlinson Energy Services 24/7 if you require steam boiler maintenance services.

5.      Leak management

This point ties back to our last two regarding steam boiler maintenance and being familiar with the boilers; there are four different types of serious leaks that any boiler operator should look out for, these include:

• Steam;
• High and low-pressure feedwater;
• Gauge glasses; and
• Safety valves.

In most cases, these types of leakages can lead to steam burns to operators or fires due to liquid spraying electrical equipment that does not have the appropriate IP rating. Leaking gauge glasses can actually explode and send glass flying as well as steam; in less serious instances a leaking gauge glass can indicate inaccurate water level measurements. It’s important to keep all boilers and components well-maintained and to never overextend their operational capacity.

6.     Handle treatment chemicals with care

Boiler water must be treated with certain chemicals such as potassium hydroxide to ensure it remains free of impurities; these chemicals can cause bodily harm to the operators if handled incorrectly. Always read the MSDS and ensure the appropriate safety precautions are being taken including wearing the proper PPE.

Australian steam boiler specialists

Tomlinson Energy Services prides itself on being Australia’s leading steam boiler and thermal energy systems vendor; specialising in complete solutions, we can assist you with all your steam boiler maintenance, sales and installation services. Our knowledgeable and experienced specialists can assist you with system selection to ensure the right product perfectly fits your operations.

If you would like to find out more about our services, then please do not hesitate to contact us by filling out the form below or calling the Tomlinson head office located in your state. 

Steam-driven machines have been around for hundreds of years and represent a tried-and-true concept that is still used today. As Australia’s leading boiler service specialists, we think it’s important for our customers to understand the origins of this revolutionary technology. From 1st century Greek civilisation to the Boulton-Watt engine — let’s take a look at the important history of steam engines.

1^st century — The Aeolipile (Heron’s engine)

What is also known to be the world’s first steam engine, the Aeolipile was created during the 1st century by a Greek named Heron. The Aeolipile consisted of a sphere with two cylindrical exhausts angled in different directions; the sphere was connected and suspended above a kettle via two pipes — which would heat water and force steam to flow through the connecting pipes into the sphere.

The steam blowing out of the two exhausts would spin the sphere — displaying one of the first examples of reactive force. Heron’s engine did not serve any known practical uses but was simply an (at the time) impressive feat of engineering and the precursor to the boilers we know and use today.

17^th century — flooded mines and the first practical applications

As coal mining became prominent in Europe, deeper mines were dug, resulting in water sources being found and flooding said mines. This is where the first practical use of a steam engine arose as Spanish inventor Jerónimo de Ayanz patented a machine that used steam to propel the water out of the mines in Guadalcanal, Seville. Later in the century, English inventor Thomas Savery patented a machine for the same purpose that also relied on steam; Savery’s model leveraged cylinders and pistons and, by 1705, his first working steam engine had been created.

Unfortunately, this iteration was not without its issues and it wasn’t long until another inventor, Thomas Newcomen, came along and remedied the flaws in Savery’s machine with a design that used atmospheric-level steam pressure (as opposed to requiring accumulated steam pressure). Newcomen’s design was used for a number of decades in the 18th century but was not very efficient, constantly requiring cold and hot water to cool and heat the steam cylinder.

18^th century — the industrial revolution

James Watt is a name well known in the boiler industry as he is the Scottish inventor and mechanical engineer known for improving Newcomen’s steam engine; these changes are said to be a vital part of the industrial revolution. Watt formulated these advances in 1756 but was unable to implement them until 1776 after he met an English manufacturer, Matthew Boulton, who was committed to using steam engines for a variety of applications and had the financial backing that Watt required.

What is known as the Boulton-Watt engine utilised a double-acting (initially a single-acting) rotative engine with an independent condenser capable of maintaining a constant temperature (solving the continuous requirement for water in Newcomen’s machine). This engine was also twice as powerful due to a parallel motion mechanism, allowed operators to control its speed with a centrifugal governor device and leveraged a new gearing system that permitted linear motion to be converted into rotative motion. The Boulton-Watt engine was revolutionary and was used for all sorts of applications over the next few centuries including the powering of factories, mills and breweries.

20^th century — water-tube boilers and becoming the modern machine

In 1766, the first water-tube boiler was built and patented by John Blakey; this was improved upon periodically over the next century. Two powerhouses of the late 19th and early 20th century, The Babcock & Wilcox Company and The Stirling Boiler Company, merged in 1907 and rebranded The Babcock & Wilcox H-type boiler to the H-type Stirling — which was capable of producing up to 50,000 pounds of steam per hour.

Boilers began to be constructed in the 1920s and ‘30s with flat studded tube walls and loose tube walls; both of these tube walls increased the heating surface via different means. As industry grew in the 1900s, so too did the need for more complex and powerful boilers — many of which were developed to meet specific requirements. Today, there are several different types of boilers, each of which is suitable for a variety of applications across multiple industries.

Are you looking for boiler service professionals in Australia?

Tomlinson Energy Service are boiler specialists who have been operating since 1892 — delivering high-quality and professional steam boiler services to all industries. We specialise in the sale and maintenance of packaged steam water boilers and stock trusted, world-renowned brands such as Weishaupt and Bosch.

If you would like to enquire about our steam boiler services, then please do not hesitate to contact us today — our knowledgeable and friendly staff are always happy to help.

Tomlinson has successfully installed and commissioned the new and improved SDGL Water tube boiler

Boiler is now fully designed to ASME

The previous design has been modified and enhanced with larger diameter water wall tubes and smaller tube pitch

Counter flow economiser engineered for gases to flow upwards improving the efficiency

Boiler is now fitted with Grundfos VSD pumps , Weishaupt duel fuel burner with VSD and O2 trim, Quality ARI Armaturen flanged valves, Gestra water level and blowdown controls .

Control panel with latest Allen Bradley PLC and HMI

Tomlinson can proudly say this is the highest quality most efficient boiler on the Australian market

Tomlinson Energy Service recently carried out an upgrade of the boiler plant at Goodman Fielder Moorebank.

The task involved the removal of two Old Woodley Boilers built in the 60’s and replacing them with 3 x 500 kw Bosch Unit. It was a full Turnkey Installation which involved replacement of all components in Boiler house including Feedwater Tank and blowdown Tank.

The Bosch unit were CSB fitted with integral Economisers , Weishaupt burners with VSD and O2 Trim and Grundfos Pumps.

The overall nett boiler efficiency is approximately 88%. The entire project was carried out by Tomlinson Installation and Commissioning Team 

Scope of project is the turnkey supply of equipment, Installation and commissioning of these three boilers, ancillary equipment and 200 meters of stainless steel steam and condensate return lines to the blancing equipment imported from Spain.

Almondco Australia is globally recognised for supplying premium quality almond products since 1944. 

More than 85% of Australia’s almond growers supply to this company – one of the most successful horticultural co-operatives in the nation.

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