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Scale, soot, and residue accumulate inside boiler tubes over time, reducing heat transfer efficiency and increasing the risk of failure. Even a thin layer of buildup (0.03 – 0.05 inches) can cut efficiency by 10% or more. Perform mechanical (brush) or chemical cleanings at least once a year to keep your boiler running efficiently.

2. Manage Boiler Blowdown to Control TDS Levels

High levels of total dissolved solids (TDSs) in boiler water can lead to scale buildup, which lowers efficiency and increases the risk of breakdowns. Implement a controlled boiler blowdown schedule to remove impurities, preventing deposits from forming and maintaining optimal water quality.

3. Monitor and Treat Water Quality Consistently

Poor water quality can cause corrosion, scaling, and system inefficiencies. Regularly test for dissolved minerals, returned condensate levels, and de-aeration efficiency. As boiler size and operating pressure increase, so should the frequency of inspections and water treatments to prevent costly damage.

4. Inspect and Maintain Insulation

Surfaces with temperatures exceeding 130°F should be properly insulated to prevent heat loss and inefficiencies. Uninsulated steam and condensate piping, valves, and fittings can drive up operating costs. Regularly inspect and repair insulation to maintain energy efficiency and protect system components.

5. Keep Accurate Service and Maintenance Logs