The Importance of Maintaining Daily Boiler Logs

Why Maintain a Boiler Log?

Boiler operators play a crucial role in ensuring the safe and efficient functioning of boilers in various industries. It is their responsibility to maintain and operate the boiler systems to ensure they function as expected and meet compliance standards.

One of the critical tasks that boiler operators need to perform daily is maintaining the boiler logs. A boiler log is a record of a day’s operating conditions, which typically includes information on fuel and water consumption, steam pressure, temperature, and other critical system parameters. Keeping accurate and up-to-date logs is essential for the smooth and safe operation of the boiler.

1. Compliance Requirements

Boiler operators need to comply with regulatory compliance standards to ensure safety and meet environmental regulations. Boiler logs are a critical document for demonstrating compliance with these regulations. Authorities will refer to the log to verify that the boiler is operating in conformance with the regulations. Failure to produce an accurate daily log can lead to significant penalties and legal implications.

2. Boiler Efficiency

Maintaining daily boiler logs is a crucial element of ensuring the optimal performance and efficiency of the system. By carefully monitoring fuel, water, and steam consumption, operators can identify patterns that suggest whether the boiler is working efficiently or experiencing inefficiencies that need to be corrected. With this information, operators can make the necessary adjustments to improve the effectiveness of the boiler and reduce operational costs.

3. Predictive Maintenance

Maintaining proper boiler logs can help operators predict when the system is likely to fail or experience problems. Daily logs form the basis of a predictive maintenance program, helping operators identify trends that suggest the need for repairs or maintenance before a major problem arises. This approach helps to prevent costly downtime and repairs by correcting minor issues before they turn into significant problems.

4. Safety

The most crucial factor when it comes to boiler systems is safety. Boiler logs play an essential role in ensuring that boilers operate safely. They help operators understand critical information about the operation of the system. For example, by monitoring steam pressure and temperature, operators can identify potential safety hazards and take corrective actions to prevent accidents or explosions.

Maintaining proper boiler logs also helps the operators understand the condition of the individual safety components that make up the boiler system. The logs help to ensure compliance with regulations, optimize the performance of the system, and prevent major problems. Boiler operators must take the task of maintaining daily logs seriously and ensure that they are accurate, up-to-date, and complete.

To conclude, it is crucial to emphasize the importance of diligently maintaining daily boiler logs. Neglecting this task can have serious repercussions on the reliability and safety of boiler systems. Boiler operators should prioritize investing sufficient time and effort into keeping thorough and up-to-date logs to guarantee optimal performance and safety.

Let your Icon Boiler representative know if your facility or organization needs assistance in establishing, maintaining, or reviewing your Boiler Log Program. 

Pumps in a Boiler System

Your boiler makes steam. That steam is under pressure. That’s just how boilers operate. But as that steam is created, it lowers the amount of water in the boiler. That means feedwater has to be added. Otherwise, two things will happen. First, you’ll eventually run out of steam, literally. The second thing that will happen without feedwater is a low water level. You don’t want that, because it creates heat stress on the tank and promotes scaling and corrosion.

But we’ve already established that a boiler is under pressure. If you just open a water valve, that water isn’t just going to pour into the boiler as the boiler feed water is typically in an atmospheric feed tank or a DA that has 5-10 psi on it. The steam pressure will more than likely push the water back up the way it came, introducing steam into parts of the boiler system that aren’t designed to handle it. That means water has to be added under pressure, and that’s why boiler systems have pumps.

Pump It Up

Pumps are responsible for introducing feedwater into the boiler under sufficient pressure that the steam can’t escape, so the boiler doesn’t lose the pressure that keeps it operating. The size and capacity of the pump on a boiler system depends on the operating pressure of the boiler, and the amount of feedwater that needs to be delivered over time. Obviously, larger boilers will have bigger pumps, and some even have multiple pumps to get the job done.

Amp It Up

Boiler pumps are electrically operated. However, the amount of current that a pump will draw doesn’t necessarily correlate to the pressure it puts out. Pumps that deliver water under higher pressure will do so at a lower volume. That’s because pressure and volume are always inversely related; raising one lowers the other, and vice versa. Another way to think about it is in terms of a garden hose. If you put your finger over the end of the hose, you can make the water come out at a higher pressure the tighter you squeeze your finger over it. But the greater the pressure, the less water actually comes out every second.

Pump Up Your Trivia

As an interesting aside, the largest steam-powered water pump in the world, which is powered by the world’s largest steam engine (with a piston diameter of more than 12 feet), is located in the Netherlands. Found in the Dutch village of Cruquius, the pump was constructed in 1850 to help drain the 45,000-acre Haarlem’s Lake to reclaim land for farming. The pump house was eventually converted into a museum, the Museum de Cruquius, and is still open today with the massive steam powered pump as its main attraction. If you’re a real steamhead, it’s definitely on your bucket (valve) list.

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Icon Boiler Achieves R-Stamp Certification

We are delighted to announce that Icon Boiler, a renowned name in the boiler industry, has successfully obtained their R-Stamp certification. This achievement further solidifies Icon Boiler’s commitment to excellence in the field of boiler manufacturing and repair.

Icon Boiler’s Commitment to Quality

Icon Boiler has always strived to deliver top-notch products and services to its clients. This achievement of R-Stamp certification is a testament to their unwavering commitment to quality and safety. With this certification, Icon Boiler is equipped to provide full service solutions including exceptional code repairs and alterations to boilers, ensuring they meet the highest standards and comply with all regulatory requirements.

Some of these common code repairs include: 

• Boiler Retubing
• Feed-water inlet coupling replacements
• Nozzle repairs
• Retacking a baffle shelf

Benefits for Clients

Obtaining the R-Stamp certification has several advantages for clients seeking boiler repair and alteration services. Some of the key benefits include:

• Quality Assurance: Clients can be confident that Icon Boiler’s repairs and alterations are performed according to the highest industry standards, ensuring the longevity and reliability of their boilers.
• Compliance: With R-Stamp certification, clients can rest assured that their boilers are in full compliance with relevant regulatory codes and standards.
• Expertise: Icon Boiler’s team of certified professionals possesses the knowledge and expertise necessary to handle even the most complex boiler repair and alteration projects, providing clients with a reliable and skilled resource.

Icon Boiler – A Trusted Partner

“Obtaining the R-Stamp certification is a significant accomplishment for our company,” said Myron Burnett, General Manager of Icon Boiler. “It demonstrates our commitment to providing safe and reliable solutions to our clients. This certification exemplifies our dedication to adhering to industry best practices and ensuring the highest level of customer satisfaction.”

Whether you require a minor repair or a complete overhaul, Icon Boiler has the expertise and capability to meet your needs. Contact the team at Icon Boiler today, and experience their commitment to exceptional service and craftsmanship firsthand.

Icon Boiler is proud to announce the completion of its Summer Internship Program, which recently welcomed two students – Jeremy and Malachi from Williamson College of the Trades in Media Pennsylvania. They traveled to Raleigh, North Carolina for an 8-week internship program, working with field experts on commercial boiler projects across North and South Carolina.

Meet Jeremy

Jeremy is presently pursuing an Associate’s degree in Specialized Technology with a major in Construction Technology at the Williamson College of the Trades. Notably, he is keenly interested in electrical work and is focusing his academic pursuits in that direction. Jeremy enjoyed the hands-on experience and the practical knowledge he gained through his internship at Icon Boiler.

Meet Malachi

Malachi is also a current undergraduate of Williamson College of the Trades, where he is earning his Associate’s Degree in Specialized Technology with a focus on Power Plant Technology. Malachi has been eager to apply his skills and learn from the experts at Icon Boiler. Malachi has a natural talent for problem-solving and is looking forward to expanding his knowledge and experience with cutting-edge boiler technology.

What They Are Doing

Jeremy and Malachi have been working alongside our experienced team of commercial boiler technicians, learning the ins and outs of boiler installation and maintenance. Their responsibilities included assisting in the installation, repair, and maintenance of different types of commercial boilers. They also supported routine maintenance tasks like cleaning boilers, replacing parts, and monitoring pressure and temperature gauges. Jeremy and Malachi are gaining valuable insights into the complex systems that keep commercial buildings warm and comfortable.

The Importance of Internship Programs

At Icon Boiler, we believe that our interns play a crucial role in our operations. Summer internships offer hands-on experience to talented young professionals, and they are a great way to identify new talent and bring fresh perspectives to our organization. Our 8-week summer internship program prioritizes practical experience, giving our interns the tools they need to succeed and advance in their careers.

We are proud to have had Jeremy and Malachi at Icon Boiler, and we’re excited to see how they grow and develop throughout their careers. Their enthusiasm and dedication to the commercial boiler industry are a testament to the future of our industry. We hope our internship program can inspire future generations of commercial boiler technicians to pursue their dreams and help us build a world where commercial buildings are efficient, sustainable, and comfortable.

Making sure your commercial boilers receive preventive maintenance is a wise decision. It not only saves you money in the long run by optimizing the efficiency of your boiler, but also extends its lifespan. Regular maintenance can also improve the safety of your workplace and significantly reduce the likelihood of emergency situations.

To ensure that your boiler stays in good working condition, it’s important to know what actions you need to take and what tasks should be arranged with your Icon technician. Refer to the maintenance checklist below for vital information on what you can do to maintain your boiler. These simple tasks include routine checks, which help detect and address issues promptly. Remember, if you encounter any problems during your routine maintenance checks, don’t hesitate to contact Icon Boiler for professional assistance to prevent the problem from becoming more serious.

Scheduled Maintenance

Completed by Icon Boiler service technician

• Test low water cutoff and exercise pressure relief valve.

• Blowdown, test low water cutoff and feed control(s).

• Check for water, steam, and fuel leaks.

• Check settings and test operating and limit control.

• Blow down water level sight glass and confirm the water level.

• Visually inspect the condition of safety relief valves for tampering and leakage.

Annual Maintenance

Completed by Icon Boiler service technician

• Secure and drain boiler annually.

• Open fireside and waterside for cleaning and inspection. 

• Inspect gauge glass and replace if necessary. 

• Clean fuel nozzles or gas burner tubes. 

• Clean combustion blower fan wheel and air dampers. 

• Clean and adjust ignition electrodes. 

• Inspect, lubricate, and tighten all linkage/jackshaft components.

• Visually inspect the condition of safety relief valves for tampering and leakage.

• Combustion testing.

• Check operation and calibration of operating controls and safety devices.

While a boiler operates on a simple principle — turning water into steam — it’s far from a simple piece of equipment. Everything inside a boiler needs to work together in harmony to maintain safe, efficient operation. If everything isn’t working together, a boiler will start to lose efficiency, which translates to wasted money in fuel costs. Believe it or not, though, most boiler problems come down to two main issues.

Water Level

Water levels in a boiler can affect performance and efficiency like nothing else. In order to work at its best, a boiler must not only start with the right amount of water, it must also maintain that water level as it operates. If a boiler’s control system can’t accurately match the feedwater supply to steam production, the water level will get out of whack, and that’s when the problems start. If your boiler isn’t operating like it’s supposed to, start by checking the water level.

Too Little Too Much Too Late

Too much water coming in will make your boiler bite off more than it can chew.  In other words, all that extra water will absorb heat, effectively cooling the temperature inside the boiler. That means lower steam production, and it means the boiler will have to burn more fuel as it struggles to make steam. If your boiler isn’t producing like it used to, or if it’s burning more fuel than normal, you may be dealing with an abundance of H20.

Too little water in the boiler is just as bad, though. When the water level drops below where it’s supposed to be, it can cause the water tubes to become exposed. If that happens, the parts of the tubes sticking out of the water will have nowhere to transfer their heat, and they’ll start to overheat. That means extra stress on the metal in the tubes, which means cracks, warping, or even ruptures. If your boiler is leaking, if it smells bad or smells “hotter” than normal, or if it’s making strange noises, make sure your water level is high enough.

Think Pure Thoughts

Most of the time, water level problems are caused by the quality of the water itself. Without clean, properly softened water, a boiler’s entire waterside can start to lose capacity and performance, which will result in getting too much or too little water in the boiler tank. 

If boiler water is too hard, the minerals and impurities it contains (especially iron) can react with the metal inside the boiler and cause corrosion. This corrosion not only weakens the boiler itself, but corrosion can also build up enough to displace the water the boiler needs in order to function properly. 

Even if the water doesn’t have a lot of iron in it, it can still cause problems. Dissolved solids that aren’t removed by softening or proper filtration will settle on the surfaces inside the waterside. When enough of this scale builds up, it can rob the boiler of feedwater flow and water capacity. Scale can also act as a heat insulator, causing inefficiency in the boiler’s operation while also creating uneven heating across the waterside surface. It can also start to clog or impede the function of other parts of the boiler such as deaerators, sparge tubes, and the preheating system.

Not Firing on All Cylinders

While the waterside can experience a lot of common issues, the fireside’s no stranger to them, either. The second most common cause of boiler issues has to do with the ability to make a consistent amount of heat to keep the water-steam equation in balance.

If a boiler can’t make enough heat, it won’t be able to convert very much water to steam. A lack of heat often has to do with the quality and consistency of fireside maintenance. Regular cleanings help prevent soot buildup, which can choke off burners and cause uneven heating. Burners also require regular inspection and tuning to make sure they’re within spec.

Without regular attention, the fireside can start to experience flameouts. When a flameout happens, excess fuel can start to build up around the malfunctioning burner. When that fuel reaches a nearby burner that is working properly, it’ll suddenly all ignite. If your fireside is rumbling, make sure your burners are all up to snuff. Be sure to check your air dampers as well, because combustion problems can also be attributed to too much or too little air.

Another common issue in the fireside has to do with control linkages. As boiler controls do their job, they tend to move around. This movement creates friction, and friction creates wear. The more the control linkage components wear down, the more play will develop in them. While that play or slack may seem insignificant, it can create enough variation in the supply of air, water, or fuel to cause your boiler to perform poorly.

How it All Stacks Up

Interestingly enough, one of the biggest indicators of boiler issues can be found at the tail end of the combustion cycle: the stack. If a boiler’s stack is running hot, that’s an indicator that something somewhere isn’t right, whether you’ve got too little water, too much fuel, or something else is out of spec. So keep an eye on your stack, and if it’s running hot, start looking for other issues that could be the cause.

Authorized Use Provided by our Partners at WARE Inc. 

If you are experiencing issues with your boiler, don’t hesitate to reach out to Icon Boiler’s team of professionals. We are always available to inspect, diagnose, repair, or replace any components in your system. Contact us today to start the conversation.