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.

Why Steam Boiler Industries Matter Now: The Impact of COVID-19 sadsad

A variety of businesses rely on steam boilers and hot water boilers to continue operating during the time of COVID-19. 

COVID-19 has left a devastating impact across the globe, severely affecting businesses, industries, and the lives of people everywhere. 

Lockdowns and curfews have caused immense hardship to businesses, causing many to close their doors and others to struggle to survive with what resources they have left. Manufacturing companies throughout Australia and around the world are making every effort to keep their operations running while maintaining health and safety standards. 

Currently, both fears and opportunities exist within the steam and boiler industry because of the current financial climate. As the pandemic grows in intensity, companies are seeking solutions to their energy systems that can survive lockdowns and curfews-and steam boilers remain one of the most reliable energy sources available.

Power plant steam boilers

Industry definition of steam boilers & heat exchangers

A primary focus of this industry is the manufacturing of steam boilers and heat exchangers. Heat exchangers are devices that transfer thermal energy between two fluids while keeping them separated. Boilers are closed vessels that heat fluids. In the energy, industrial, and commercial markets, boilers and heat exchangers are widely used.

However, despite the fact that the boiler industry primarily focuses on manufacturing boilers, maintenance is a key aspect of the field. 

To maintain their efficiency, boilers need regular maintenance. When they are not maintained, they become less and less efficient, and they eventually may pose a danger in the form of leaks or even explosions to those who are working around them.

Maintenance is one aspect of the industry that has been impacted.

In many countries and across Australia, social distancing and lockdowns have made it difficult for steam and boiler maintenance companies to provide services such as routine inspections and maintenance. 

Despite these challenges, a few boiler repair businesses have remained open, and have issued statements and protocols on COVID-19 and continue to offer their services.

Fortunately, many of them have vowed to stay in their industries. Business professionals are doing their very best to provide industrial boiler maintenance, handle emergency shutdowns, or perform scheduled boiler maintenance.

The role of steam boilers in essential sectors

In spite of its financial impact, COVID-19 has provided steam and boiler manufacturers with numerous opportunities. 

Steam and hot water are produced by steam boilers and hot water boilers for a variety of essential services. As well as being crucial to homes, they are also vital for hospitals, manufacturing businesses, and power plants. 

Safe operation of boilers is essential to the following sectors and assets:

            Hospitals and Pharmaceutical Companies. Boilers provide a variety of essential services to hospitals and pharmaceutical companies, including the provision of heat to hospital buildings as well as steam sterilization and manufacturing and maintaining the drug production lines. Hospitals are required to regularly repair boiler systems and boilers in order to ensure proper operation with an increasing number of COVID-19 cases.

            Food Processing Industries. In order to create and process food, food processing businesses are dedicated to boilers – without properly functioning boilers, many food processing facilities would likely come to a standstill. 

            Power Plants and Industrial Buildings. In addition to electric power plants and industrial buildings, steam boilers play an important role in almost any industrial or power generation facility.

Despite COVID-19 causing a lockdown on businesses, these industries still provide essential services to our daily lives. Because of this, steam and boiler industry professionals are essential to the smooth operation of these large and vital operations.

Steam and boiler industry professionals are responsible for keeping these sectors working on a regular basis. This includes installing and maintaining steam boilers, handling potential complications, and providing energy solutions.

Energy Efficiency: A Key Factor

After the Coronavirus, many industries have to adopt energy-saving measures in order to recover quickly. After a series of economic shocks, factories and industries that depend on boilers will need high-efficiency boilers that can improve production and allow them to recover losses. 

To ensure that boilers remain energy efficient, regular maintenance is vital. 

Regular maintenance doesn’t just save money, it increases boiler energy efficiency and reduces environmental damage. 

Steam boiler plant worker

Safety at Work 

Steam boiler maintenance service is an essential service, so safety is of the utmost importance for these maintenance workers.

It is imperative that gas engineers, technicians, and other personnel practice proper sanitation while handling emergencies close to burners, controls, and pumps. 

When it comes to installing steam boilers, dealing with emergency shutdowns, or maintaining energy systems, workers practice safety procedures at all times. 

As part of regular maintenance, boiler inspectors are implementing these steps

Looking for a steam boiler specialist in Australia?

Tomlinson Energy Service provides 24/7 emergency and service support to the Asia-Pacific markets supplying high-efficiency packages for steam boilers, hot water and thermal oil heaters, offering in-house technology from prestigious brands including Bosch and Weishaupt.

Contact us today or simply fill out the enquiry form below If you would like to enquire about our steam boiler services. Our industry knowledgeable experts are here to help!

Steam Boiler Breakdown: Fire Tube vs. Water Tube sadsad

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.

Understanding Boiler Blowdown and Selecting the Right Vessel sadsad

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.

6 Key Considerations for the Ideal Boiler Room sadsad

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 — InstallationAS 2593 Boilers — Safety Management and Supervision SystemsAS 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 systemsgas 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.

Steam Boiler Safety 101: 6 Protocols you Should Follow sadsad

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. 

The History of the Steam Engine: A Revolutionary Concept sadsad

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.

1st 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.

17th 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.

18th 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.

20th 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 JTPB 3SDGL sadsad

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