Packaged Steam Boiler 101 sadsad

In the industrial landscape of Australia, there is a constant need for efficient, reliable, and compact steam boilers. This is where packaged steam water boilers step in, as a great solution that encapsulates simplicity and efficiency. This month, we explore the world of packaged steam water boilers, and their design, benefits, applications, and how they contribute to streamlined operations in many industries across the country. Plus, learn about the importance of steam boiler maintenance for packaged steam water boilers to ensure their safety and efficiency.

Understanding Packaged Steam Boilers

So, what are packaged steam boilers? These are comprehensive units that integrate both a steam generator and a water boiler into a single, compact package. This makes packaged steam boilers a highly functional product that streamlines the production of steam and hot water, which means that they can cater to the diverse needs of various industries. Their design incorporates essential components like burners, controls, and safety features, ensuring that they are a holistic system that is both efficient and easy to install.

Compact Design for Efficiency

One of the major drawcards of packaged steam boilers is their compact design, and this compactness also contributes to their efficiency. These boilers are engineered to occupy minimal space, making them ideal for facilities with spatial constraints. Because they are compact, they are relatively simple to install, and they also enhance overall energy efficiency due to the fact that they reduce the heat losses associated with lengthy pipelines. In addition, the integration of components within a confined space promotes better heat transfer, resulting in faster response times and increased energy utilisation.

Versatility in Applications

Packaged steam boilers fuel applications across a variety of different industries. From manufacturing and hospitals to educational institutions and food processing, these boilers are critical in many ways. Their ability to produce both steam and hot water makes them adaptable, which not only adds to their utility but also makes them a cost-effective choice for businesses with multifaceted requirements.

Energy Efficiency and Environmental Impact

Packaged steam boilers also have the added benefit of environmentally friendliness. Their streamlined design and advanced combustion systems optimise fuel-to-steam and fuel-to-water efficiency, translating into tangible energy savings for businesses. This makes them an attractive choice because of their cost-effectiveness, and to address environmental concerns. By reducing fuel consumption, packaged boilers are able to curtail greenhouse gas emissions and contribute to a cleaner and more sustainable industrial landscape. Packaged steam boilers play a pivotal role in fostering a sustainable balance between industrial productivity needs, and environmental-friendliness.

Safety Features for Operational Confidence

Safety is paramount in industrial settings, and packaged steam boilers incorporate advanced safety features. These features often include pressure relief valves, water level controls, and flame safeguards. The integration of these safety mechanisms within the compact design ensures that these boilers operate within specified parameters, mitigating risks associated with pressure fluctuations, water level imbalances, or combustion irregularities.

Cost-Effectiveness

The initial investment in a packaged steam boiler is often justified by the long-term cost-effectiveness that it brings to businesses. The efficiency gains, reduced fuel consumption, and streamlined maintenance translate into significant operational cost savings over the life of the boiler. In addition, the adaptability of these boilers to various applications ensures that businesses can optimise their processes without the need for separate, specialised systems.

Installation and Maintenance

In terms of maintenance and installation, packaged steam water boilers are the epitome of efficiency and simplicity. Because of their compact design, the installation process can be expedited, requiring less installation time than larger, more intricate systems. Further, the streamlined design of these boilers also simplifies routine maintenance procedures. With all of the key components integrated into a single unit, accessibility for inspections and servicing is enhanced, which minimises downtime and ensures sustained operational efficiency. Packaged steam boilers often include advanced control systems that offer precise adjustments to operational parameters and contribute to the overall ease of management. This not only streamlines the initial installation but also simplifies ongoing steam boiler maintenance, which is a cornerstone of responsible and safe boiler operation.

Do You Need Steam Boiler Maintenance?

Then look no further than Tomlinson Energy Service. We are proud to be the experts in boiler maintenance and repair, and installation. Backed by 100 years of engineering and service experience, and can provide you with unparalleled steam boiler expertise.

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

A Comprehensive Guide to Emergency Steam Boiler Repairs in Australia sadsad

Steam boilers play a pivotal role in various industries across Australia, providing essential heat and power for numerous processes. However, the unexpected breakdown of a steam boiler can bring operations to a standstill, leading to potential losses and safety concerns. In this guide, we’ll navigate through the intricacies of emergency boiler repair in Australia. From understanding common issues to implementing swift and effective solutions, this guide aims to empower facility managers, operators, and maintenance teams with the knowledge required to respond decisively in times of crisis.

Identifying Common Boiler Issues

The first step in navigating emergency boiler repairs is recognizing the signs of trouble. Common issues that can lead to emergency situations include:

Pressure Fluctuations: Sudden changes in pressure may indicate problems with valves, regulators, or water levels.

Leaks and Water Damage: Leaks can compromise the structural integrity of the boiler, leading to potential hazards.

Unusual Noises: Odd sounds, such as banging or whistling, can be indicative of issues like water hammer or steam traps malfunctioning.

Decreased Efficiency: A sudden drop in efficiency may suggest scaling, corrosion, or combustion problems.

Flame Irregularities: Irregularities in the flame pattern can signal combustion issues, impacting both efficiency and safety.

Immediate Response Protocols

When faced with a steam boiler emergency, a swift and well-coordinated response is crucial. The following protocols should be implemented:

Emergency Shutdown: Immediately shut down the boiler to prevent further damage. Follow the established emergency shutdown procedures.

Isolate the System: Isolate the affected boiler from the rest of the system to contain the issue.

Ensure Safety: Prioritise the safety of personnel. Evacuate the area if necessary and follow established safety protocols.

Notify Authorities: In compliance with Australian regulations, notify relevant authorities about the emergency situation.

Document the Situation: Document the incident, capturing details such as pressure readings, temperature, and any visible damages. This information will be valuable during the repair assessment.

Calling in the Experts

Engaging with boiler professionals who specialise in emergency steam boiler repair is paramount. When selecting a repair team, consider the following:

Expertise: Ensure that the repair team has extensive experience in steam boiler systems and emergency repairs.

Response Time: Assess the team’s ability to respond promptly to emergencies. Quick action is critical in mitigating damage.

Certifications and Compliance: Verify that the repair team complies with Australian safety standards and holds relevant certifications.

References: Check references and reviews to gauge the team’s reputation for reliability and competence.

24/7 Availability: Emergencies can happen at any time. Confirm that the repair team offers around-the-clock availability for emergency calls.

Assessment and Diagnosis

Once the emergency repair team is on-site, a thorough assessment and diagnosis are conducted:

Visual Inspection: The boiler is inspected externally for visible damages, leaks, or abnormalities.

Internal Examination: If deemed safe, internal components are then inspected for wear, corrosion, or any other issues.

Testing: Comprehensive testing is conducted, including pressure tests, to identify the root cause of the emergency.

Data Analysis: Data that was collected during the incident is analysed to gain insights into the events leading up to the emergency.

Report Generation: A detailed report is generated, outlining the assessment findings, recommended repairs, and any necessary replacements.

Swift and Effective Repairs

With a clear understanding of the issue, the repair process can commence:

Component Replacement: Damaged or malfunctioning components are replaced with high-quality, compatible parts.

Welding and Machining: If applicable, welding and machining may be necessary to restore structural integrity.

Scaling and Corrosion Removal: Scaling and corrosion issues are addressed through descaling procedures and the application of protective coatings.

Control System Checks: The functionality of control systems is verified, ensuring that they respond accurately to operational demands.

Testing: After repairs, thorough testing is conducted, including pressure tests and operational tests, to ensure the boiler’s functionality and safety.

Post-Repair Evaluation and Preventative Measures

The completion of emergency repairs marks the beginning of post-repair evaluation and preventive measures:

Continuous Monitoring: Implement continuous monitoring of the boiler’s performance to detect any anomalies early on.

Preventative Maintenance: Establish a robust preventative maintenance schedule to address potential issues before they escalate.

Operator Training: Ensure that operators are well-trained in emergency response procedures and routine maintenance tasks.

Data Analysis for Continuous Improvement: Analyse data collected during the emergency and repair process to identify opportunities for continuous improvement.

Documentation: Maintain detailed documentation of the emergency, repair process, and post-repair activities for future reference.

Do You Need Emergency Steam Boiler Repair?

If you find yourself with a steam boiler emergency on your hands, who do you call? The answer is Tomlinson Energy Service. Emergency steam boiler repair demands a strategic and decisive approach, and by engaging with the right repair professionals, you can navigate emergency boiler issues with confidence. With over 100 years of engineering and service experience, rest assured that we can help. We proudly bring you unparalleled expertise in installing, maintaining, and repairing steam boilers.

Whether you need emergency repairs or installation, you can call us at your state-specific phone number, or fill out our online contact form.

Off-Site Valve Repair for Steam Boilers: 3 Questions Answered sadsad

When it comes to steam boiler maintenance the efficiency and reliability of important components such as valves, is absolutely critical. Off-site valve repair is a strategic solution that can address issues with valves, and also enhance their overall performance. We are here to comprehensively answer three questions you might have about off-site valve repair, so that you have the information you need to make an informed decision about off-site repairs and maintenance. Learn all about the process, advantages, and more, plus be armed with the knowledge you need to help you maintain the safety and efficiency of your steam boiler.

1: What is Off-Site Valve Repair?

This type of repair involves the careful and skilled disassembly, inspection, refurbishment, and reassembly of valves away from the boiler site itself. There are many advantages to this approach, and many maintenance experts provide this service because of the benefits when compared with traditional on-site repairs.

Due to the fact that the valves can be transported to specialised facilities, this means that trained and expert technicians are able to work with them alongside advanced technology and tools. This in turn leads to the ability to conduct a more thorough evaluation, and thus more comprehensive repairs. Off-site repairs offer a more meticulous and holistic repair process because the approach doesn’t have the same constraints that technicians may face in an on-site environment. They are also particularly appropriate for critical valves, as these demand precision and attention to detail because of their importance.

2: What are the Advantages of Off-Site Valve Repair?

Comprehensive Inspection: These off-site repair facilities are better equipped than an on-site environment as they have specialised tools as well as diagnostic equipment. This means it is a better and more specialised environment in which to provide a detailed inspection, and ensures that all the valve components are thoroughly examined. During a comprehensive inspection, technicians are able to use advanced technology to check valves for signs of wear and tear, damage, or potential issues.

Precision Repairs: In an off-site repair environment, these trained technicians are able to perform precise repairs such as welding, component replacements, and machining. On-site, it can be difficult to achieve this level of precision, especially when it comes to intricate valves.

Quality Assurance: Off-site valve repair facilities must adhere to strict quality control measures, ensuring that repairs meet all industry standards. This in turn helps to ensure that valves that have been refurbished undergo stringent and rigorous testing before they are returned to service in their boiler system.

Reduced Downtime: This approach to boiler repair can actually reduce downtime for your boiler because the repair of valves is carried out independently of the boiler operation. Whatever your industry, this is a significant advantage as it helps you to minimise any interruptions and also maintain consistency and operational efficiency.

Enhanced Safety: When valve repairs take place off-site, this contributes to improved safety. This is due to the fact that there are reduced risks associated with off-site repairs when compared with on-site repairs, and they take place in a more controlled environment.

3: What is the Off-Site Valve Repair Process?

Valve Removal and Transportation: This first step involves safely removing the valve from the steam boiler system. Once it has been removed, the valve is then carefully transported to the off-site repair facility, which may involve packaging and logistics considerations. This then helps to prevent damage during the transit process.

Comprehensive Inspection: Once the valve arrives at the off-site facility, it undergoes a thorough inspection. This step includes an assessment of all the internal and external components of the valve, as well as identification of wear, corrosion, or any other issues that can affect performance.

Disassembly and Cleaning: The next step involves disassembling the valve, and then meticulously cleaning each component. This is a crucial part of the overall process, as it removes scale, debris, or contaminants that can accumulate during regular operation.

Repair and Refurbishment: Next, the technicians carry out any necessary repairs like matching, welding, or the replacement of damaged components. This ensures that the valve is restored to its optimal working condition.

Testing and Quality Assurance: After refurbishment, valves undergo rigorous testing to make sure that they meet the specified performance standards. This can involve pressure testing, leakage checks, and functional tests to help ensure that the valve can operate safely and as intended.

Documentation and Certification: Next, the entire repair process is documented, and the valve in question is certified. This provides a record of repairs, and also verifies that the valve meets industry standards.

Transportation and Reinstallation: The final step is the safe transportation of the valve back to the boiler site, where the skilled technicians reinstall it and ensure proper alignment and integration with the boiler system.

Do You Require Steam Boiler Maintenance or Off-Site Valve Repair?

Then Tomlinson Energy Service is here to help. We are proud to bring you the very best in expertise in boiler maintenance, installation, and repair, alongside unparalleled customer service. We can help with off-site valve repair, or any of your boiler maintenance needs.

Get in touch with us by calling your state-specific telephone number, or fill out our online contact form, and we will help with your enquiry.

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

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

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.

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

What is steam distribution in steam boilers?

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

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

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

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

Condensate build-up

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

Steam leakage

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

Uneven steam distribution

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

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

Water hammer

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

Corrosion

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

How to fix these steam boiler issues? 

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

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

Does your business need steam boiler experts?

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

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

4 Uses of Dry Steam in Industrial Applications sadsad

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

Dry Steam in Food Processing and Production

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

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

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

Steam Purity and Dry Steam in Sterilisation Processes

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

Dry Steam and Boiler Lifespan

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

Dry Steam and Paper Production

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

Do You Need Steam Boiler Experts?

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

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

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

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

How Long Should a Boiler Last?

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

Regular Maintenance

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

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

Check Water Quality

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

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

Know When to Replace

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

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

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

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

Do You Need Experts in Steam Boilers?

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

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

Steam Boilers – What Are The Main Types? sadsad

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

A Short History of Boilers

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

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

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

Fire Tube Boilers

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

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

1      Wet and Dry Back Boilers

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

2      Multi Pass Boilers

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

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

Water Tube Boilers

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

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

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

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

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