How Do You Maintain and Clean a Chemical Oil Fired Boiler

Introduction

As a professional industrial boiler manufacturer, EPCB boiler has always been committed to providing efficient and reliable thermal energy solutions to customers all over the world. Among many products, chemical oil-fired boiler is widely used in various chemical industries because of their high thermal efficiency and stable operation. However, no matter how advanced the equipment is, it also needs scientific maintenance and regular cleaning, so as to maintain a good running state, prolong its service life and reduce its running cost. Next, EPCB boiler will focus on the theme of "how to maintain and clean the oil-fired boiler for chemical industry", and introduce the key points and best practices that need to be paid attention to in actual operation to help users realize the efficient and safe operation of boiler equipment.

Importance of Maintenance and Cleaning

In daily industrial operation, chemical oil fired boiler is the core energy equipment, and its working state is directly related to production efficiency, safety and operating cost. Although many enterprises pay attention to performance indicators in the initial stage of equipment procurement, in the actual use process, they ignore the later maintenance and cleaning work, which leads to the decline of efficiency, the increase of energy consumption and even the potential safety hazard. In fact, scientific and regular maintenance and cleaning is not only the basic requirement to ensure the normal operation of boilers, but also the key to enhance economic benefits and corporate image.

1. Improve boiler thermal efficiency and reduce fuel consumption and operating costs.

During the long-term operation of chemical oil fired boiler, oil stains, smoke and scale are easy to accumulate on the inner wall of furnace, heat exchange surface and combustion system. These deposits will hinder the effective conduction of heat, reduce the thermal efficiency of the boiler, and lead to an increase in fuel consumption. Cleaning the boiler regularly can effectively remove these impurities, restore the best heat exchange state of the equipment and significantly improve the thermal efficiency, thus helping enterprises to reduce energy consumption and operating costs.

2. Prevent failures, prolong the service life of boilers and reduce the risk of unexpected shutdown.

Boiler belongs to continuous operation equipment. If it lacks regular maintenance, it is easy to break down due to aging parts, pipe blockage or imbalance of combustion system. This not only affects normal production, but also may lead to sudden shutdown and economic losses. Through regular inspection and maintenance, potential hidden dangers can be found in time, and vulnerable parts can be replaced and repaired, thus prolonging the overall service life of the boiler and ensuring the stability of the production process.

3. Ensure compliance with safety regulations and reduce the accident rate.

The chemical industry requires high safety of equipment, especially in chemical oil fired boiler system. If the maintenance is not in place, it may lead to serious accidents such as fuel leakage, deflagration or carbon monoxide leakage. Regular maintenance and cleaning can not only ensure the normal operation of key devices such as combustion system, pressure system and safety valve, but also help to comply with relevant local safety regulations and industry standards, reduce safety risks caused by equipment failure, and ensure the personal safety of operators.

4. Reduce emissions, improve indoor air quality and meet environmental protection requirements.

With the increasingly strict environmental protection laws and regulations, pollutants such as soot and nitrogen oxides emitted by boilers need to be controlled within the scope of compliance. Carbon deposition and residue will lead to incomplete combustion, thus increasing pollutant emissions. By cleaning the burner, flue and exhaust system regularly, the combustion process can be ensured to be more complete and the emission cleaner. At the same time, it is also helpful to improve the air quality of boiler room and working area, create a healthier working environment and show the environmental responsibility of enterprises.

Maintenance and Cleaning

Daily Inspection

Daily inspection is the most basic and key link in boiler maintenance, especially in chemical oil fired boiler system. Through daily regular inspection, the running status of equipment can be grasped in time and potential problems can be prevented.

1. Fuel oil level check

Fuel is the basis of stable operation of boiler. Checking the oil level of the fuel tank daily can ensure the continuous and stable combustion process and avoid problems such as flameout and startup failure caused by oil supply interruption. At the same time, it is also necessary to pay attention to whether there is a risk of overflow if the oil level is too high to prevent potential safety hazards. For the equipment with automatic refueling system, check whether the sensor and refueling control system work normally.

2. Monitoring of operation parameters

Real-time monitoring of boiler operating parameters, including furnace temperature, pressure, flue gas temperature, water level and burner status, is an important basis for judging whether the boiler is operating normally. Recording and comparing the fluctuation of parameters every day is helpful for early detection of anomalies, such as abnormal pressure rise and severe temperature fluctuation, which may indicate internal scaling, blockage or decreased combustion efficiency.

3. Abnormal sound and vibration

The boiler should be stable and quiet during operation. During the daily inspection, it is necessary to pay attention to whether there is any abnormal knocking sound, vibration sound or metal rubbing sound, which may be the signal of pump, fan, motor or combustion system failure. Especially in the startup and shutdown stages, we should pay more attention to whether the sound and vibration are abnormal, so as to deal with them as soon as possible and avoid minor problems from turning into major failures.

4. Safety device function

Various safety devices (such as safety valve, pressure switch, gas leakage alarm, carbon monoxide alarm, emergency stop button, etc.) equipped with boilers must be checked daily for their normal functions. It is a key measure to ensure personal and equipment safety to confirm that these devices can respond quickly in an emergency through simulated operation or system self-check function.

Weekly Inspection

Different from daily inspection, weekly inspection focuses more on the preliminary evaluation of boiler external system and working environment. Through regular external inspection and system inspection, we can find some problems that are not easy to detect in daily operation, and further consolidate the safety and reliability of boiler operation.

1.Fuel pipeline leakage inspection

Once the fuel pipeline leaks, it will not only waste energy, but also cause serious accidents such as fire or explosion. Every week, check whether there is oil leakage, oil dripping, corrosion or looseness in oil pipes, joints, valves and other parts. At the same time, observe whether there is oil residue on the ground, and judge whether there is abnormal oil smell by smell. For boilers equipped with automatic fuel supply system, it is also necessary to check whether the pressure is stable to prevent pressure fluctuation caused by leakage.

2. The surrounding environment is clean

The environment of boiler room directly affects the operation safety of equipment. The surrounding environment of the boiler shall be thoroughly cleaned once a week, including removing dust, oil stain and debris accumulation, so as to ensure that the boiler and its auxiliary equipment are well ventilated and unobstructed. In particular, key areas such as burner air inlet, control cabinet, electrical box and smoke exhaust passage should be kept clean and tidy to prevent failure or fire risk caused by dust or foreign matter accumulation.

3. Electrical connection inspection

After the long-term operation of the electrical part of the boiler system, the terminals may be loose due to thermal expansion and contraction or vibration, and the lines may be aging and worn. Every week, we should check whether the cable connections of the control system, burners, fans, pumps and other major power-consuming parts are firm, and whether the wires are damaged, aged or overheated. At the same time, confirm that the grounding system is effective, ensure electrical safety, and prevent short circuit or leakage accidents.

Monthly Inspection

Compared with daily and weekly basic inspection, monthly inspection pays more attention to the running state and performance of boiler core components. Through in-depth inspection of air system, combustion system and emission system, the combustion efficiency of boiler can be effectively improved, pollution emission can be reduced, and the basis for subsequent maintenance can be provided.

1.Air filter maintenance

Air filter is an important part of boiler combustion system, which is used to filter the air entering the burner, prevent dust and impurities from entering the combustion chamber and affect the combustion effect. Once the air filter is blocked, it will lead to insufficient air intake and insufficient combustion, increase energy consumption and produce black smoke. Clean or replace the air filter at least once a month, especially in the boiler room with more dust or poor ventilation. The maintenance frequency should be appropriately increased according to the actual situation on site to ensure clean and sufficient combustion air.

2. Burner inspection

Burner is the "heart" of boiler system, and its working state directly determines the combustion efficiency and safety. Check the flame stability of the burner, the response speed of the ignition system, the nozzle wear and the uniformity of fuel injection every month. If abnormal flame color (such as yellowish and smoky), delayed ignition or increased combustion noise are found, the nozzle should be cleaned in time, the aging parts should be replaced, and the combustion parameters should be calibrated. In addition, check whether the connection between the burner and the boiler body is firm to prevent air leakage or displacement.

3. Flue gas emission

The flue gas discharged from boilers may contain harmful gases such as carbon dioxide, nitrogen oxides and carbon monoxide, which is the focus of environmental protection supervision. The flue gas emission should be monitored every month to assess whether it meets the local environmental protection standards. If it is found that the emission index exceeds the standard, check whether the combustion condition is normal, whether there are problems such as insufficient combustion and improper fuel-air ratio. At the same time, the inner wall of the flue can be inspected to see if there is carbon deposition and blockage, so as to ensure the smooth discharge of flue gas and avoid the back pressure from affecting the operating efficiency of the boiler.

Annual Maintenance

Annual maintenance is the most comprehensive and in-depth part of boiler maintenance system, aiming at comprehensively restoring equipment performance through systematic inspection and cleaning, eliminating potential failure risks and ensuring efficient and safe operation of boilers in the next year. The following are the key contents of annual maintenance:

1 . External inspection and cleaning

Visually inspect the boiler shell every year to see if there are any signs of damage such as sag, crack and corrosion; At the same time, check all control components, such as valves, pressure gauges and control panels, to ensure clear identification and normal function. Clean the external surface of the boiler and the surrounding environment of the equipment, remove dust, oil stains and obstacles, keep the ventilation smooth, and meet the safe operation conditions.

2. Internal cleaning and inspection

After thoroughly stopping cooling and cutting off power and oil, conduct a comprehensive inspection on the inside of the boiler. Comprises the following steps: disassembling the burner for deep cleaning of nozzles and fuel injectors; Remove the dust and residue in the combustion chamber and flue; Check whether the refractory is worn; Check the boiler tubes for scaling, corrosion or cracks, and record all abnormalities, and contact professional and technical personnel for handling if necessary.

3. Burner maintenance

Clean the combustion nozzle regularly to ensure smooth injection without blockage; Check whether the ignition electrode and its related components are in good condition to ensure rapid and reliable ignition; If necessary, readjust the burner to make the fuel burn fully, reduce emissions and improve combustion efficiency.

4. Fuel system maintenance

Check the fuel tank for leakage or pollution, and clean the fuel tank if necessary; Check whether all oil pipes are firmly connected to avoid oil leakage caused by cracks or looseness; Replace fuel filter according to maintenance plan to prevent impurities from affecting system operation.

5. Electrical system inspection

Check the electrical connection points comprehensively to confirm that there is no looseness, ablation and aging; Verify whether the grounding system is reliable to prevent electric shock or equipment damage; Test the safety control system to ensure that it can give an alarm in time or stop automatically when a fault occurs.

6. Security check

Check the release function of the safety valve to ensure that the pressure can be discharged in time in case of overpressure; Check whether the flue and ventilation system are unobstructed and whether there is any risk of blockage or leakage; Check whether there is fuel or waste gas leakage, and pay attention to whether there is abnormal smell to avoid carbon monoxide poisoning or explosion.

7. Record keeping and documentation

Establish an annual maintenance log, which records the inspection date, implementers, implemented projects and problems found in detail; Keep relevant maintenance records, test reports and other documents for future traceability, and meet the needs of safety audit and regulatory compliance.

Conclusion

As an important energy equipment in industrial production, chemical oil-fired boilers can not operate efficiently, safely and environmentally without scientific and systematic maintenance and cleaning. Through daily, weekly, monthly and annual classified inspection and maintenance, not only can the thermal efficiency of boilers be significantly improved, but also the energy consumption can be reduced, and the service life of equipment can be effectively prolonged, and the failure rate and shutdown loss can be reduced.

As a professional boiler manufacturer, EPCB always emphasizes the concept of "maintenance is more important than repair" and advocates users to establish a complete boiler management system to ensure the stable operation of boilers from the source. Whether checking the fuel system, electrical system or cleaning the burner and flue, all steps should be standardized and detailed, and detailed records should be made to lay a solid foundation for the long-term use and safe operation of the equipment.

Only by integrating daily maintenance into every detail of enterprise operation can we really give full play to the maximum efficiency of boiler equipment and help enterprises achieve green, efficient and sustainable development goals.