PEMELIHARAAN HARIAN DI RUANG BOILER

Michael Taylor sebagai Kepala Departemen Keselamatan, akan menjelaskan perawatan harian di
ruang boiler.
A. BLOWDOWN BAGIAN DASAR BOILER (BOTTOM BOILER BLOW DOWN)

Hal utama yang harus dilakukan adalah mengeluarkan semua padatan dari boiler yang
terakumulasi di blowdown. Padatan bisa jatuh atau turun ke dasar karena beratnya lebih
besar dari air. Bahan kimia yang ada didalam boiler dapat mencegah menempelnya
padatan tersebut ke tabung dan bahan lainnya.

Pada kebanyakan Boiler, Blowdown utama memiliki katup pembukaan cepat dan katup
pembukaan lambat. Pilihlah pembukaan cepat dulu. Contohnya, akan dikeluarkannya
lereng yaang telah mengendap.
1. Pastikan katup terbuka penuh
2. Pastikan tidak menekan pipa, agar tidak meledak.
3. Perhatikan instruksi berapa lama proses pembuanganya
4. Segera tutup katup jika telah selesai.

B. MENGHANCURKAN KOLOM AIR

Kolom air digunakan untuk mengontrol ketinggian air di boiler dan untuk mencegah blower
keluar batas. Di dalamnya ada sakelar yang akan mematikan burner jika air terlalu rendah.
Proses pengendapan akan mengendap di sebuah wadah yang sama seperti yang terjadi di bagian
bawah boiler. Jadi jika dibiarkan terlalu banyak, maka probe tidak akan mengambil sedikit
kondisi air. Proses peledakan dilakukan untuk meledakkan sedimen. Selama tidak ada probe,
proses dapat dilakukan cepat.
1. Burner pada boiler harus dimatikan karena pemotongan air rendah, sehingga dapat
mematikan air juga dari sakelar itu. Begitu pula jika ada sesuatu yang salah, burner harus
dimatikan lalu melihat apa yang salah.
2. Buka katup sepenuhnya
3. Biarkan keluar
4. Tutup kembali katup

C. MENCATAT TEKANAN DAN TEMPERATUR BOILER

1. Periksa tekanan boiler ketika keadaannya steady load
Perhatikan pada saat proses, karena suatu saat akan ada di titik dimana bola akan
berfluktuasi tergantung pada beban. Jadi, periksa tekanan saat menambahkan
beban tetap, bukan saat mendapat lonjakan beban besar/beban stabil. Dan periksa
untuk memastikan bahwa lubang mempertahankan tekanan.
2. Simpan buku log harian dari tekanan di boiler
Catat hasil pemeriksaan tekanan di log book.
 D. MENCATAT SUHU TUMPUKAN
Suhu tumpukan dicatat untuk memastikan beban terhadap boiler, memastikan beban
tidam berubah, serta memastikan papan berfungsi dengan baik.
(SKALA LEBIH BANYAK = LEBIH BANYAK PANAS KELUAR)
Tumpukan dalam suhu tumpukan akan memberi tahu apa yang terjadi di dalam boiler.
Timbangan dan jelaga adalah penyekat yang bagus, salah satunya akan mengurangi efisiensi dan
memungkinkan lebih banyak panas untuk keluar dari tumpukan.
(SUHU TUMPUKAN HARUS ANTARA 50-100 DERAJAT DI ATAS SUHU UAP)
Jika suhu uap 325 derajat maka stok akan berada di antara 375 dan 425. Jika melebihi itu maka
ada sesuatu yang rusak di dalam papan. Bisa masalah suet masalah penskalaan.
E. MEMERIKSA TEKANAN GAS
1. Periksa untuk memastikan tekanan baik dari Gas Supply

Sangat penting untuk memeriksa dan memastikan bahwa pasokan gas baik dan
regulator bekerja dengan pengukur. Jika berhenti bekerja harus di periksa.
Pemeriksaan tekanan ini menjadi beban harian yang baik untuk memastikan
semuanya sesuai.

2. Sebagai pengukuran vakum meningkat, perlu adanya pengubahan filter.

Di gerbang belakang, kita akan mengetahui apakah filter macet atau tidak.
Filter diganti saat operasi dihentikan dan pengukur naik dalam ruang hampa.

F. MEMERIKSA KERUSAKAN NYALA API ATAU JELAGA YANG MUNGKIN

1. Mencari konsistensi nyala api
a. Cek bagian belakang boiler untuk memeriksa kondisi nyala api, apakah
tetap atau berubah
b. Setiap boiler memiliki nyala api normal yang berbeda, namun jika sudah
terbiasa kita akan tahu yang tetap atau normal itu yang seperti apa.
2. Pelampiasan Nyala api artinya nyala api telah berputar mengenai sisi.

G. MELIHAT PERALATAN PENDUKUNG

1. Periksa setiap hari pompa kimia untuk memastikan mengalir ke sistem. Tidak ada
kebocoran, bahan kimia yang cukup, pompa berjalan dengan sesuai
2. Selalu periksa suhu tangki untuk mencegah kejutan atau shocking boiler
3. Pastikan untuk memeriksa garam didalam air softener.
Harus memeriksa garam setiap hari untuk memastikan garam Gus di pelembut
Anda untuk memastikan semua hal itu bekerja dengan baik seperti yang
seharusnya. Garam yang benar inilah yang membersihkan garam dan membulat,
sehingga mereka bisa melakukan pekerjaan ini.
 H. MEMERIKSA KUALITAS AIR ANDA
1. Ambil sampel setiap hari untuk memeriksa konsistensi kualitas atau memastikan
bahwa air yang masuk baik serta memastikan bahan kimia di blowdown bekerja
dengan baik.
2. Ambil sampel make up water
a. Ambil sampel make up water dan soft water
b. Pastikan bahan kimia yang mana yang cocok untuk proses. Karena
setiap jenis air membutuhkan jenis bahan kimia yang berbeda juga.
Apakah air yang lebih lembut atau menggunakan air deionisasi atau
yang lain
3. Ambil sampel air didalam tangki untuk melihat apa air Anda dan melihat berapa
banyak bahan kimia yang perlu di tambahkan.
4. Ambil sampel air boiler untuk melihat apakah program kimia Anda bekerja di
papan dan program blowdown Anda berfungsi atau dengan benar.
Kegagalan peralatan boiler bisa berbahaya dan biasanya mengakibatkan hilangnya produktivitas,
dan penskalaan pendapatan boiler di sisi air akan menyebabkan panas berlebih dan akibatnya
dalam kegagalan boiler. Jika hal ini terjadi terkadang dapat terjadi kegagalan bencana yang
mengakibatkan ledakan sisi air atau sisi api, hal ini memiliki konsekuensi yang lebih serius
karena termasuk benar-benar melukai atau mungkin bahkan kematian dan kemungkinan
kerusakan fasilitas dengan rencana pemeliharaan pencegahan yang tepat, masalah ini dapat
dihindari atau sangat dihindari. dikurangi.
Well today on the boiling point we are going to talk about daily maintenance on your boiler
room.
THE BOILLING POINT
DAILY MAINTENANCE IN THE BOILER ROOM
Welcome to the boiling point. We are here with 36 year veteran Michael Taylor. Michael’s
actually in our safety department and heads all to the safety department of where but more
importantly he’s last word technically in the business so 36 years in the business got a lot of
knowledge and so really. I can’t believe I haven’t had you on the boiling point yet so glad that
you are finally with we are talking about today we are going to talk a little bit about daily
maintenance of the boiler and taking care of the boiler and we thought we’d go through a
checklist of things that you could do on a daily basis. So Michael the first thing. I believe that we
would do is look a little bit about the blow downs.

BOTTOM BOILER BLOW DOWN

SOLIDS FALL DUE TO THEM BEING HEAVIER THAN WATER
The biggest point is to the main blowdown to get all the solids out of the boiler that’s
accumulated in there.
Okay, how those solids actually get to the bottom blowdown.
And they are heavier than the water so they are going to fall to the bottom the chemical in the
boiler actually keeps it from attaching to the tubes and the other materials so they can’t drop and
you can blow them out.
Okay, so this is a daily thing that should be done once you go through that process real quick for
us.
Okay, I main blowdown you are going to have quick opening and a slow opening on most
boilers. You always open the quick opening first, it’s just a backup you don’t want to open it last.
You want to open the slope make sure that you don’t stress the pipes and stuff and blow them
off, so you open the valve up all the way and depending on how long your chemical guide tells
you to blow it then you close it back down. Typically it’s going to be a ten second blow.
Okay and then shut your secondary valve back off
BLOWING DOWN THE WATER COLUMN
THE WATER COLUMN CONTROLS THE WATER LEVEL IN THE BOILER
All right we have moved to the front of the boiler now we are going to be doing the water
columns, Michael first of all what the water column is for.
It’s to control the level of the water in the boiler and to prevent the blower from going out on low
water. So it has switches in it that will shut the burner off if the water gets too low.
Okay, so what are we going to do going to daily maintenance on this.
Well this you have settlement will settle in this bowl just like it does in the bottom the boiler, so
if you let it too much build in there then the float or the probes in this case, will not they take
little water conditions. So you have to blow that column down to blow all that sediment out. And
on this one it’s a probe so it doesn’t matter how quickly you do it but if you have got a float in
there you have to do it very slowly or you will collapse your float. So you simply open the valve
up all the way, the time you get it open it’s blown out so then you close it back down
Okay so it’s not a ten second here
THE BURNER SHOULD SHUT DOWN DUE TO LOW WATER CUTOFF
No just open up and close it back down. And when you do that the boiler the burner should shut
down because it’s going to drop the water off that switch if it doesn’t shut down, there is
something wrong you need to shut it down and see what’s wrong with it.
RECORDING BOILER PRESSURE AND TEMPERATURE
Well having data is always important and this next thing that we are going to do is something
that is also important tell us a little bit about the boiler pressure.
CHECK YOUR BOILER PRESSURE WHEN YOU HAVE STEADY LOAD
Plea depending on your process you are going to have a certain set point on your boiler pressure.
And the ball it’s going to fluctuate some depending on your load. So you always want to check
your pressure when you add a steady load, right not when it’s you have got a big load surge or
it’s back way off whenever its steady load and check to make sure that your bores maintaining
the pressure.
KEEP A DAILY LOG BOOK OF THE PRESSURES IN THE BOILER
Is this something that you would actually write down daily?
Sure you should have a daily log book that you would write that down a lot of places they will
record that every hour.
RECORDING STACK TEMPERATURE
And what would you use that information for?
Just to see what your load is being on your board to make sure that your boiler is big enough and
also to make sure that if your load hasn’t changed that your boards working properly
Well we have moved back to the back of the boiler again and the stack seems to be something
that is really important to understand once you tell us a little about the stack.
(MORE SCALE = MORE HEAT ESCAPING)
Well the stack will in stack temperature will tell you what’s going on inside the boiler, because
scale is a great insulator, soot is a great insulator either one of them is going to cut down the
efficiency and allow more heat to go out your stack.
(STACK TEMPERATURE SHOULD BE BETWEEN 50-100 DEGREES ABOVE STEAM
TEMP)
Okay, so if you check your stack temperature daily the stack temperature should always be from
1500 degrees above your steam temperature.
Okay, so if you have got 325 degrees steam temperature 225 psi then your stocks going be
between 375 and 425 if gets out of that it starts rising you know something is going haywire
inside the board.
Okay, and typically when that stock temperature is going up a lot of times it is a suet problem
and maybe a scaling problem something like.
It’s going to be one of the other either acid or scaling and either one makes it well really
inefficient because you are sending more heat out instead of transferring it to your 16.
CHECKING THE GAS PRESSURE
Okay all right well we have moved to the fuel side of things and what do we do with gas here
Mike
CHECK TO MAKE SURE YOUR PRESSURE IS GOOD FROM GAS SUPPLY
Well you got your gas very buddy which is regulating your gas going to the burner, so it’s real
important that you check to make sure that you’re, you got a good gas supply to it and that your
regulator is working with the gauge after the regulator. If it stops working you guess what you
should check it but it’s a good daily load to load those pressure to make sure everything is
supposed to be.
AS THE VACUUM GAUGE RISES, YOU KNOW YOU NEED TO CHANGE YOUR FILTER
Okay now that’s gas now what about oil?
With oil you have an old filter and you have a back engage between the pump and the filter and
that backing gates will tell you. That the filter is getting stuck when those filters getting stopped
up. Okay, so as the gauge rises in vacuum, you know to need to change your filter out.
Okay so no fuel probably hard for the burner to work
Yes very hard
CHECKING FOR FLAME IMPINGEMENTS OR POSSIBLE SOOTING
YOU NEED TO LOOK FOR FLAME CONSISTENCY
Well we come back to the back of the boiler again and we are actually going to look into the site
board for looking at the flame I remember as a little kid I’d be hanging out with my dad not
always going to the boiler room and I always felt like a big boiler man because I could look into
the site port. So I still don’t know what I’m looking at mike so why don’t you tell us a little bit
about what are we looking for in here.
Well we are looking for to make sure that the flames stays, like it always is every boiler is
different but you will get used to what the flame looks like so then when something goes how
you are like the diffuser or something on the burner head you will know it because you have
been looking in there every day you say hey something changed. So then you will know to call
somebody or to check into something and you also look and see if you are building up clinkers or
anything because you can see the Morrison to when you are looking there with the flame in it,
you can see all that area so you can see if something is building up in there and causing a
problem.
FLAME IMPINGEMENT MEANS THE FLAME HAS TURNED TO HIT THE SIDES
Okay what why don’t you explain flame impingement what that
Flame impingement means that you have your flame is actually instead of going straight down
the tube it’s varying to one side or up or down and really hitting on the metal hard and then it
won’t allow it to burn. So it will start building up carbon which is unburnt fuel and what we call
in the boy industry it’s a Deadman and it will it can get pretty big in there and actually start
closing off the area so in the mold that grows the more engagement you have so the worse it gets.
Okay so something really important that this needs to become something that you are just very
familiar with your flame it’s just understanding it it’s just nice and it’s just as gaudy.
No just look through that every day or several times a day and you get accustomed to what it’s
supposed to look like and soon as something changes you know it right off the bat because you
are used to see it.
LOOKING AT THE SUPPORTING EQUIPMENT
Well Obviously the boiler is something that important and we should really look at but man there
is a lot of support equipment that goes with a boiler so why don’t we talk a little bit about the
next step and that is some off the support equipment.
CHECK YOUR CHEMICAL PUMPS TO MAKE SURE IT IS FLOWING INTO THE
SYSTEM
Okay you got the feed tank or da tank depending on your application. Here we have a regular
condensate tank and we have got a chemical pump here that is feeding chemical into the system.
You always check every day to make sure that. One you have got an ample amount of chemical
and that you haven’t got any leaks and the pump is actually pumping.
ALWAYS CHECK THE TEMPERATURE OF THE TANK TO PREVENT SHOCKING
BOILER
Okay then on top of that you have a this tank is also heated you heat the water up so that the bore
doesn’t have to work so hard so that you don’t shock the boiler so there’s temperature gauge on
here and a heater that speed steam into the tank so you always want to check that to make sure
you’re here is working probably you are not shocking damaging you bowler from cold water
right.
MAKE SURE TO CHECK THE SALT LEVELS INSIDE OF YOUR WATER SOFTENERS
Okay then you can have water softeners and other, chemical feed tanks, you have to check the
salt every day to make sure to Gus salt in your softeners to make sure all those things are
working properly like the supposed to be.
Okay so real important to just check the salt levels.
Right salt is what cleans the salt and round, so they can do this job.
CHECKING YOUR WATER QUALITY
Okay alright well now we are into water quality which we know is something that’s extremely
important and a lot of folks really don’t take care of so you know talking a little bit about the
water quality and actually how we even know that the quality is good what do we what do.
TAKE SAMPLES EVERYDAY TO CHECK YOUR QUALITY CONSISTENCY
Well it takes samples every day to make sure that your water coming in is good and that what
you are doing with your chemicals and your blowdown is working for them
TAKE A SAMPLE OF YOUR MAKE UP WATER
So first you take a sample of your make up water with its soft water city water or what it is to see
that its maintaining where you thought it was so that you know what that your chemical program
is going to work. Because you’re chemical program is set up depending on what this water is.
Which is different in every area because of the hardness of the water?
Because of the hardness of the water whether you are on a softer or you are on deionized water
what kind of water supply you have.
TAKE A SAMPLE OF YOUR TANK WATER
Okay then you are going to have to take a sample of your tank. To see because you have got time
state coming back which is distilled water so you don’t have any solids in it not but you are
making up water so you have got a mixture. So you have to take a sample back down here to see
what your water is see how much chemicals you need to add.
TAKE A SAMPLE OF YOUR BOILER WATER
A then you take a sample of your boiler water. So you can take it you will have a sample port set
up on the ball or someplace this one is on the site glass you would take it right after you did your
bro down that way you have got fresh water in it so you can take your sample to see if your
chemical program is working in the board and your blowdown program is or properly.
Okay right well if you want to learn a little bit more about the water softeners, you can click or
rate here and we actually did a boiling point on the water softeners and actually how they work
so make sure you check those out. I believe that’s it we have covered all the daily maintenance
this is something that we are going to back each every other week and we are going to be talking
about more than room maintenance from a daily basis from a weekly basis you know from some
annual type things that you need to do so tune in next time mike appreciate you hanging out with
us and we will see you next time on the boiling point.
We appreciate mike stopping by and talking to us a little bit about the daily boiler maintenance,
you know boiler equipment failures they can be dangerous and they typically result in lost
productivity, and revenue scaling a boiler on the water side will cause overheating and those
result in boiler failure. When this occurs sometimes there can be catastrophic failures that result
in a water side or fire side explosions, this has more serious consequence as including actually
injures or maybe even death and possible facility damage with the right preventative
maintenance plan these issues can be avoided or greatly reduced.