Boiler & Cooling Tower Operation & Maintenance
 
A boiler is a closed vessel in which water is heated, steam is generated, superheated or any combination thereof under pressure or vacuum by the direct application of heat. Boilers are classified by their pressure capacity, their design type and by their use.


The boiler operator is responsible for operating and maintaining the boiler in a safe and efficient manner through the use of sound engineering practices and manufacturer’s specified maintenance procedures. Most boilers accidents are caused by operator error and poor maintenance.

The Sr. Engineer of a boiler plant holds the responsibility for directing boiler operations, procedures and maintenance. The information used by the Sr. Engineer comes from the manufacturer’s recommendation the ASME and NBIC codes and generally accepted maintenance practices.

Log sheet are a proper record of boiler operation and maintenance and should be used in all boiler rooms to help ensure safe operation. A log sheet will specify the task to be performed such as blowing down the low water cut-out (LWCO) and the operator can then mark the sheet to show that the operation was completed.
 
 
 
Boiler Water Treatment: The primary goal of boiler water treatment is to control solids that cause deposits in the boiler and control gases that cause corrosion. There are three phases of water treatment in a boiler system:

 
Blowdown, which maintains the TDS (Total Dissolved Solids) in the system
External Treatment, which removes, hard salts, minerals and oxygen before the water enters the boiler.
Internal Treatment, which maintains proper water chemistry by adding chemical additives to the boiler water.
 
     

Cooling Tower

The cooling tower is often the forgotten component of the water cooling system when it comes to maintenance. It’s a good example of the phrase, “out of sight, out of mind”. A newly installed cooling tower reliably delivers the design fluid temperature and flow rate. However, since its heat transfer operation creates a hurricane like environment and is a natural air-washer, the cooling tower needs routing inspection and maintenance to continue performing as designed.
 
Performing routine preventive maintenance is paramount for consistently achieving the desired temperature & flow rate and plays an important role in maximizing cooling tower operating life. These procedures can prevent loss of efficiency in the heat transfer section by maintaining proper water flow and airflow, as well as prevents corrosion in the cooling tower. Hence, the standardized maintenance procedures should be maintained for optimized circulating water system operation.

Cooling tower components must be kept clean and free of obstructions, because temperature matters. Neglecting the cooling tower will lead to higher than desired return water temperatures to the system, which will result in higher energy use from two perspectives.
 
First the system (chiller) will consume more energy because it must operate at a higher than necessary condensing pressure (head) to satisfy the load, due to the higher fluid temperatures provided by the cooling tower. As little as 2^F (1^C) higher temperature can result in 6% more energy being consumed by the chiller.
Second the tower must operate longer at higher fan horoscope while trying to attain the design cold water temperature.
 
 
 
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