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CASE STUDIES

Boiler Maintenance Overhaul

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Background

Client operates a facility with four boilers, each approximately 8 years old. According to the manufacturer, the expected lifespan of these boilers ranges from 15 to 30 years, contingent on factors such as maintenance, usage, installation quality, environmental conditions, and model design. Despite their age, these boilers had not undergone any maintenance since installation, leading to severe operational issues.

Challenge

The client faced significant issues due to the lack of boiler maintenance:

Immediate Problem: One of the boilers was not providing heat, and upon inspection, it was found to be in a deteriorated state.

Boiler Condition: The boiler exhibited severe shaking during operation and would shut off with a loud popping noise. The burner tubes and igniter were damaged, and the system had never been properly maintained.

Debris and Buildup: Heavy debris, soot, and calcium buildup were discovered, causing over-pressurization and incomplete combustion.

Solution

Initial Assessment and Emergency Service

  • A service call was performed to address the no-heat issue.
  • Technicians found the boiler in bad shape, with significant internal damage and debris.

Comprehensive Repairs

  • All burner tubes, gas trains, and the heat exchanger access panel were removed.
  • Technicians found heavy debris at the base of the boiler and substantial soot and calcium buildup.
  • The clogged heat exchanger and burner tubes were causing over-pressurization and incomplete combustion.
  • Necessary repairs were completed, including replacing damaged parts.
  • The boiler was reassembled and tested to ensure it operated without shaking.
  • The system was monitored to confirm it reached the proper temperature.

Maintenance Schedule Implementation

  • The client was placed on a regular maintenance schedule to ensure ongoing boiler health and efficiency.
  • Technicians educated the client on the importance of regular maintenance and proper boiler care.

Strategic Asset Management Plan

  • A comprehensive plan was developed for all critical assets, including budgeting and planning solutions for future maintenance and replacements.
  • The plan emphasized proactive maintenance to extend the lifespan of the boilers and prevent future issues.

Outcome

Restored Functionality: The boiler system was restored to proper operation, providing reliable heating without issues.

Increased Efficiency: Regular maintenance significantly improved the efficiency and performance of the boilers.

Client Education: The client gained a deeper understanding of their boiler system and the importance of maintenance, leading to better asset management.

Proactive Planning: The developed maintenance and budgeting plan ensured long-term reliability and cost savings.

Key Takeaways

Problem Identification

  • The boilers were not working properly due to a lack of maintenance, causing inadequate heating and severe operational issues.

Cause Analysis

  • The root cause was identified as a complete lack of regular maintenance, leading to debris buildup and component failure.

Immediate Action

  • Addressed immediate safety concerns and restored heating by performing emergency repairs and thorough cleaning.

Maintenance Plan

  • Developed a robust maintenance plan, including regular inspections, cleaning, and servicing by qualified HVAC technicians.

Repair and Replacement

  • Repaired damaged components and restored the boiler to full functionality. Emphasized the importance of ongoing maintenance to avoid future breakdowns.

Training and Awareness

  • Educated client personnel on recognizing boiler issues and the importance of regular maintenance.

Documentation and Tracking

  • Implemented detailed record-keeping for all maintenance activities, inspections, and repairs to monitor boiler performance over time.

Budgeting

  • Allocated resources for regular maintenance and potential future repairs, highlighting the cost-effectiveness of preventative maintenance.

Continuous Improvement

  • Periodically reviewed and adjusted the maintenance plan based on feedback and evolving best practices to ensure optimal boiler performance.
“The transformation in our boiler system has been remarkable. Thanks to Peterson, our boilers are running efficiently, and we now understand the critical importance of regular maintenance. Their expertise and support have been invaluable.”

This case study outlines the critical steps taken to address the boiler issues, emphasizing the importance of regular maintenance and the long-term benefits of proactive asset management. Customize it with specific details and client testimonials to enhance its impact.

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