What Are Some Of The Common Challenges of Using a Commercial Boiler?


A malfunctioning or broken commercial boiler can disrupt your business’s operations. If you are relying on commercial boilers to heat water for your office or run your dry cleaning and laundry business, your commercial boiler system needs to run smoothly. You should provide your staff with
industrial steam boiler operator training so that they can carefully monitor it and repair any problem. Remember that regular maintenance of your commercial boiler is the best way to keep it in excellent working condition.

In case there is any major issue with your commercial boiler system, you can get in touch with an industrial boiler service provider.

Here is a list of common challenges that you might experience while using a commercial boiler.

Challenge #1 – Reduced Heat Production

Several issues can result in low heat getting produced in your boiler. This problem can also be a result of dirty burners that prevent heat from getting through. To prevent this issue from happening, you must regularly check your boiler’s burners and ensure that they are properly cleaned. If dust and debris get clogged inside the burner, it can lead to a serious fire hazard. 

There are several other reasons for low or no heat production. These can include a malfunctioning thermostat, a damaged ignition, a broken pump, or problems in the safety switch that cause the boiler to turn off automatically. You should contact an industrial hvac solutions to have a look at the problem and repair it. 

Challenge #2 – Unusual Noises

Boilers can sometimes produce strange and unusual noises, such as bubbling or gurgling. Two potential reasons for these sounds can be trapped air in the circulation system and damaged pumps. These sounds could indicate a more serious issue, such as the accumulation of limescale. These noises will not stop on their own and it is wise to seek expert guidance to resolve this issue. 

Challenge #3 – Lack of Pressure

If your boiler is working at optimum capacity, the steam pressure should remain constant within the high and low points. If you notice low pressure in your boiler, then you should check for a steam leak. Remember that a steam leak might not always be visible unless you specifically check for it. Loss of pressure can also result because of issues in the return system, such as feed pumps, steam traps, or the valve. 

Another reason for low pressure can be an under-sized heating element. An under-sized heating element will not be able to properly boil the water in the tank. This can result in the production of low steam. 

Challenge #4 – Water Leakage

Water leaks can occur anywhere in the system. For instance, water can escape from the system through air vents. Since these leaks are hidden, it can be difficult to detect them. To check if your boiler is losing water, you can use a water meter. If you don’t have this meter present on your boiler, you should get an expert to install it. 

Water leakages in a closed-loop system will cause the water level to drop low enough to turn off the system. If the water level does not fall significantly, but there is leakage in the system, it could indicate that atmospheric pressure is entering into the system. This can ultimately result in your system getting worn-out prematurely. 

In an open-loop system, a rise in the amount of the water in the tank can signal loss of water in any other part of the boiler. 

Challenge #4 – Leakage of the Expansion Tank

Even though this problem is rare, you should keep an eye out for it. If you notice any leaks from your boiler, it could indicate a serious underlying problem that may require immediate repair by an expert technician. These underlying problems could be related to the pressure relief valve, the expansion tank. It could also indicate the boiler is rusting or corroding. This often requires replacement. 

Challenge #5 – Improper Blowdowns

Improper blowdowns or a lack of blowdowns on a regular basis can result in an accumulation of solids in the boiler. This can reduce its heating capacity. To maintain water conductivity in normal limits, you must adjust surface blowdowns. Also, make sure that you conduct bottom blowdowns regularly to avoid build-up. 

Poor heating efficiency can result in higher operating costs. However, the bigger problem is that the build-up can damage the level controls and pollute the probes meant to identify a low water condition. 

Challenge #6 – Missing Insulation

 Insulation helps to contain heat in the boiler system. If the heat is allowed to escape, a larger quantity of fuel is required to maintain proper pressure and temperature. Therefore, missing insulation can significantly lower your boiler system’s efficiency. 

Since the absence of insulation may not be noticeable, it is best to check it using a thermal imager. If you don’t have a thermal imager, you can contact a plumber or a professional. 

Pro-tip – The best way to detect missing insulation is to compare your costs with the boiler usage. If your costs have risen without an increase in boiler usage, it is likely that there is missing insulation. 

Challenge #7 –Malfunctioning Fans

This is a mechanical issue and needs to be carefully investigated before any faults are formally detected. Remember that the reset button will not repair any faults in the fan. 

If the fan starts running slowly or doesn’t run at all, then there could be a problem with the wiring or connection. Extreme vibration of the fan can result in the frame getting dislodged. Moreover, there could be an accumulation of debris. 

Final Word

In a commercial boiler system, prevention is the best form of care. Therefore, you must have a regular maintenance schedule for your commercial boiler. However, if you don’t have a maintenance schedule or have started experiencing any of the problems, you can contact our boiler system support team at Campbell-Sevey.

What Are Some Of The Common Challenges of Using a Commercial Boiler?