Tag: industrial steam boiler

Energy Efficiency and Steam Boilers: 7 Tips for Australian Industries sadsad

Posted on by Multi Mode

Steam boilers play a dynamic role in many Australian industries and because of this, optimising energy usage is not only a matter of environmental responsibility, but a crucial factor in economic sustainability. As steam boilers are fundamental to various processes, they actually offer significant opportunities for energy improvements. This month, we explore key tips and strategies for industries in Australia to enhance the energy efficiency of their steam boilers. From innovative technologies to steam boiler maintenance, these insights are designed to guide industry and operators towards more cost-effective and sustainable steam boiler usage.

1: Optimal Combustion Control

A fundamental component to energy-efficient steam boiler operation is efficient combustion. Regular inspections and maintenance ensure that boilers are clean and functioning optimally. You can also consider upgrading to advanced combustion controls which allow for precise monitoring and adjustment of the air-to-fuel ratio , 02 trim, variable speed drives and improving burner turndown. This minimises fuel wastage and maximises the energy extracted from the fuel, which in turn contributes to overall efficiency.

2: Implement Heat Recovery Systems

Heat recovery systems capture and reuse waste heat from various processes, significantly boosting energy efficiency. Incorporating these systems into steam boiler operations allows industries to utilise excess heat for preheating feedwater, space heating, or even electricity generation. Common heat recovery methods include condensing economisers and flue gas heat exchangers. By extracting additional energy from the combustion process, industries can reduce their reliance on external energy sources and enhance the overall steam boiler efficiency.

3: Upgrade to High Efficiency Boilers

It is also worth considering upgrading to high-efficiency boilers which are designed to optimise fuel utilisation and minimise heat losses. Modern boilers often incorporate advanced technologies, like condensing heat exchangers. These boilers are designed to achieve higher thermal efficiency, which translates into lower fuel consumption and operating costs. The long-term savings and environmental benefits make these high-efficiency boilers a smart strategic choice for those committed to boiler energy efficiency.

4: Optimise Boiler Load

Steam boilers are most efficient when they are operating at or near their rated capacity. Running boilers at partial loads for extended periods can lead to inefficiencies and increased energy consumption. Implement strategies to optimise boiler load, such as sequencing multiple boilers for better matching of load demands or incorporating variable frequency drives (VDFs) to modulate burner output based on demand. By aligning boiler operation with actual load requirements, industries can avoid unnecessary energy consumption and enhance overall system efficiency.

5: Invest in Energy-Efficient Controls

Upgrading to advanced control systems can significantly improve the energy efficiency of steam boilers. Programmable Logic Controllers (PLCs) and advanced automation systems allow for precise control over various parameters. These systems enable better control over fuel and air flow, combustion rates, and temperature, and they are also capable of matching boiler operation with actual demand. Integrate smart controls with real-time monitoring and data analytics and this further enhances the ability to identify inefficiencies, which in turn contributes to energy savings.

6: Real Time Monitoring and Data Analytics

When real time monitoring is combined with data analytics, this empowers industries to gain insights into boiler performance and also identify opportunities for improvement. These systems provide key metrics such as fuel consumption, emissions, and efficiency. By analysing this data, operators can pinpoint inefficiencies, track the impact of operational changes, and implement targeted improvements. This data driven approach allows for continuous optimisation, ensuring that steam boilers operate at peak efficiency levels, and supporting a culture of ongoing improvement.

7: Regular Inspections and Maintenance

The foundation of energy efficiency in steam boilers lies in proactive inspections and regular maintenance. Smaller issues such as scaling, leaks, or malfunctioning components actually greatly impact efficiency over time. That’s why scheduled maintenance is essential, and should include cleaning and part replacement. In turn, regular inspections should encompass the boiler itself, as well as associated components such as burners, controls, and safety devices. Addressing potential problems promptly is critical to maintaining boiler performance and safety, and to avoiding energy wastage.

Do You Need Professional Steam Boiler Maintenance?

Look no further than Tomlinson Energy Service. We are backed by over 100 years of engineering and service experience, and we understand the critical importance of steam boiler maintenance. We are proud to provide you with unparalleled experience in boiler maintenance, repair, and installation and when you need to purchase a steam boiler, we are ready to help with that too.

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 take care of your enquiry.

6 Common Issues with Steam Boilers and How to Fix Them sadsad

Posted on by Multi Mode

We know that steam boilers are the workhorses of many Australian industries because they provide essential heat and power. However, it is also true that steam boilers are complex machines, and like any piece of complex machinery, they can encounter issues or problems. These issues can in turn affect steam boiler performance, efficiency, and importantly, safety.

This month, we dive into some of the common issues that may affect your steam boiler, and explore the most effective solutions. When you understand the potential challenges and know how to tackle them, you will help to make your workplace a safer and more efficient environment, and your steam boiler more reliable. Plus, keep reading to ensure that you know where to go for steam boiler maintenance, an important factor in mitigating steam boiler issues.

1: Low Water Levels:

Low water levels in steam boilers can be a critical issue that, if not addressed as a matter of urgency, can lead to overheating, reduced steam production, and in the most extreme cases, serious boiler damage. In order to fix this issue, boiler operators must regularly check and maintain water levels by utilising reliable water level indicators. If low water levels are discovered, the first immediate action to take is to shut down the boiler to prevent any damage. Next, after the boiler has totally cooled down, it can be refiled with water and then safely restarted.

2: Scaling and Corrosion:

Another common problem seen in steam boilers is scaling and corrosion, and this is particularly prevalent when the water quality is low. When there is scale build-up, this reduces heat transfer efficiency, and on the other hand corrosion weakens boiler components. To prevent this, regular water quality testing and chemical treatment programs are essential. Descaling is common practice to address scaling, and this is carried out using the appropriate chemicals. Further, proper water treatment and maintenance schedules can help to prevent scaling and corrosion issues and even potentially extend the lifespan of your boiler.

3: Pressure Fluctuations

There are many factors that can influence pressure fluctuations in steam boilers, from improper settings, faulty pressure regulators, or load variations. These fluctuations can affect the consistency of steam supply, and can even damage the boiler itself. To fix pressure issues, boiler operators must regularly check and calibrate pressure controls, ensuring that they are set within the specified range. Further, adjusting the burner settings and optimising load management can also help to stabilise pressure. Additionally, regular maintenance and inspections can help to identify and address pressure-related problems before they can escalate.

4: Fuel Combustion Problems

Efficient fuel combustion is essential for steam boiler performance. Problems like incomplete combustion can lead to soot build-up, as well as reduced efficiency, and increased emissions. In order to address combustion issues, operators must inspect burners regularly, clean or replace clogged nozzles, and optimise air-to-fuel ratios. Fine-tuning the combustion process has the added benefits of improved efficiency, and a reduced environmental impact. Remember that proper training is the key to combustion control, as is the case with overall steam boiler operation. Plus, regular combustion system maintenance is also essential to both resolving and preventing these issues.

5: Safety Valve Problems

Safety valves are a vital component of steam boilers that prevent excessive pressure build-up. However, they are susceptible to developing issues like leakage, rust, or improper settings. To fix these problems with safety valves, steam boiler operators should test them regularly, ensuring that they open and close as designed. In addition, leaking safety valves must be repaired or replaced urgently, and any rust must be addressed through protective coatings, and proper maintenance. Lastly, operators must ensure that safety valves are correctly set to the required pressure limits in order to maintain steam boiler safety.

6: Steam Leaks

When a boiler has a steam leak, this not only wastes energy but also reduces the efficiency of the entire steam boiler. Common causes of steam leaks include damaged or worn-out gaskets, seals, or valves. In order to fix steam leaks, operators must once again conduct regular inspections of the entire steam boiler system, including valves, fittings, and joints. Leaking components must be replaced or repaired as needed. In addition, proper insulation can also help to prevent heat loss and reduce the risk of steam leaks. Further, if a steam system management program can be implemented which includes leak detection and repair, this can also improve boiler efficiency.

Do You Need Steam Boiler Maintenance?

You don’t have to look any further than Tomlinson Energy Service. Backed by over 100 years of engineering and service experience, we are ready to assist you with all your steam boiler maintenance needs. We proudly bring you unparalleled expertise in installing, maintaining, and repairing steam boilers, and as a member of the Environmental Group Limited (EGL), we are also committed to the protection of the environment.

Whether 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 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.

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.

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

Posted on by Multi Mode

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!