October is ideal time to make sure your boiler is ready before the first freeze hits. If your commercial facility has an older boiler or boiler with high runtime, the earlier you can inspect it the better. Stocking up on boiler parts now is a smart way to ensure you’ll have essential components available the second you need them, preventing downtime, cold indoor environments, and costly emergency service calls.
Top Boiler Parts to Keep On-Hand
Common Boiler Problems and Their Solutions
Clogged Components
There are various components that require cleaning to keep proper functionality. Burners and igniters can become soot-covered, clogging them up. When this happens, complete combustion can be hard to achieve, affecting heating capabilities, and you’ll also have higher fuel use. Cleaning the burners and ignitors before the cold months begin will ensure your boiler has efficient combustion and heats properly. As a bonus, burner and igniter cleaning can boost fuel efficiency by up to 15%, saving on energy costs.
In addition, as steam boilers heat water, sludge and sediment build up on the bottom of the boiler, reducing heat transfer efficiency. The blowdown valve, located near the bottom of the boiler, will release a high-pressure flow of water, cleaning out the muck. Hitting this valve bi-annually will improve the heat transfer abilities of the boiler, but make sure the condensate return tank is refilled with water afterwards so you have accurate water levels.
Pressure Relief Valve Failure
Failure of the pressure relief valve can result in overpressure conditions, increasing the likelihood of an explosion. Pressure relief valves should be tested annually. This can be done by carefully lifting the lever on the valve and observing the discharge pipe. There should be a rush of water when lifted, and then a complete seal when released. If there is only a trickle of water or the valve fails to reseal fully, then the valve is likely malfunctioning and needs immediate replacement. If your facility uses a steam boiler, testing is much more complex and should only be done by a qualified, professional boiler technician.
Worn/Torn Overused Gaskets
Over time and with repeat disassembly/reassembly during preventative maintenance cycles, gaskets will crack or lose their seal, leading to water, steam, or even combustion/flue gas leakage. This poses safety risks and also reduces boiler efficiency. Leaking water can also cause additional damage to other boiler components or property if it finds its way outside of the boiler. During your annual inspection, always check gaskets for wear and tear and replace any that are losing its seal.
Faulty Controls
Malfunctioning controls can cause erratic firing and complete boiler shutdowns. They can also lead to safety hazards from improper pressure, water levels, or temperature. Controls should be tested and calibrated annually to ensure boiler uptime, safe operation, and improved fuel efficiency.
No Flame
The flame is crucial to the combustion process, so without it, the boiler will fail to heat. The flame sensor is key to this. Flame sensors are safety devices that detect the flame. If no flame is detected, a signal is sent to the boiler’s control board to turn off the fuel supply so gas does not build up in the boiler, preventing explosions and carbon monoxide poisoning. Flame sensors are susceptible to dirt or carbon buildup, so they should be cleaned annually with steel wool or very fine sandpaper (make sure to not use an abrasive material), and inspected to ensure no physical damage, faulty wiring, or misalignment.
Low Water Levels
Low water levels in boilers and insufficient pressure in heating water systems can lead to vital component damage and overheating, increasing the risk of explosion. While doing your inspection before heating season begins, you’ll want to verify water levels and check the low water cutoff (LWCO) to make sure it’s working. Low water cutoffs kill the fuel supply if the water level drops below safe levels. You can test the LWCO by setting the burner to a low firing rate, opening the blowdown valve, and then monitoring the sight glass. If the boiler shuts down before reaching the minimum safe water level mark, then you’ll know it’s working properly. The valve can then be closed, the pump restarted, and the burner will restart once the water level rises.
Boiler Maintenance Checklist
Perform these steps to make sure your boiler is ready for heating season.
- Inspect and clean burners.
- Test and calibrate controls.
- Verify water level sensors and feedwater system.
- Test pressure relief valves.
- Replace worn gaskets and seals.
- Check insulation on pipes and ducts.
- Activate blowdown valves.
- Schedule annual boiler servicing and ensure Electronic Combustion Analysis and burner tuning are performed.
- Keep a log of all inspections or maintenance done, particularly if performed by multiple people, to monitor any variances that can indicate issues over time.
Buy your backup boiler parts now from LONG PartsPros and make sure you’re prepared to solve any issues your boiler may have when it matters most.