Dennis MillerMarketing ManagerB&W Energy Services

MAKING THE BEST DECISION FOR YOUR

NEW BOILER

MAKING THE BEST DECISION FOR YOUR NEW BOILER

Proper pre-commissioning is vitally

important to the life expectancy and

long-term efficiency of industrial

machineries and equipment.

If neglected or poorly pre-

commissioned, new boilers can turn

into old boilers years before their

time. Making the wrong decision

in the pre-commissioning stage

will lead to an exponential loss of

efficiency and profits.

To effect the maximum cost savings and

increased profits, pre-commissioning

cleaning must be performed by

knowledgeable teams who understand

the intricacies of your particular system.

B&W Energy Services is committed

to informing you of all the resources

available to make the best decision

based on sound practices and decades

of experience. For new boilers especially,

it is critical that every detail be taken

into account and all cleaning options be

thoroughly explored to make the most

of your investment.

Boiler tubes containing mill scale

and other deposits create long-term

reliability problems for the boiler.

Deposits insulate the water in the tubes

from the fire, which causes the metal

temperature to increase dramatically

between the mill scale and the tube

metal. Long-term overheating of the

metal will result in reduced efficiency

from prolonged operation with heavy

tube deposits. The tubes will first bulge

and then fail. Because the deposits tend

to be widespread, this generally means

that large sections of boiler tubing will

be damaged and require replacement.

The increased metal temperature

generated by these deposits increases

the rate of corrosion caused by

any phosphate, caustic, or chloride

underneath the deposits. With the

exception of corrosion fatigue, all the

waterside boiler tube failure mechanisms

occur under these deposits. Get rid of

the mill scale and other deposits and

you reduce the waterside tube

failures, allowing for maximum

unit life expectancy.

Unfortunately, in many cases, the

practice of trial and error during

the pre-commissioning and

commissioning stages continues

to be a common approach in

our industry. When choosing the

proper method for your system it

is all-important to partner with a

company who will take the time

to detail their process and fully

explain every option available to

save valuable time and optimize

your investment. No one does

this better than B&W Energy

Services.

PRE-OPERATIONAL CLEANING

Most pre-operational cleaning

methods include as a minimum a boil-

out or hot degreasing. The internal

surfaces of a new boiler will contain

elements inherent in manufacturing

procedures, such as grease, protective

coating, and residual oil. To remove

these deposits, a boil-out or hot

degreasing may be sufficient, but

it will not address the removal of

potentially harmful new construction

debris, mill scale, and weld slag that

will adversely effect boiler efficiency

and operating costs. In order to reduce

operational shutdowns and delays

due to reduced heat transfer and

premature tube failure, a full, one step

degreasing and acid cleaning should

be considered.

• Type of design, amount of flow, operating temperature, and pressure of the steam generator

• Characteristics and quantity of deposits

• Compatibility of the cleaning solvent with system metallurgy

• Method of spent solvent disposal

• Availability of demineralized water or condensate

• Safety and cost

CONSIDER THIS WHEN DECIDING ON THE BEST METHOD FOR YOUR NEW BOILER

Typically, the OEM provider has

set a standard minimum cleaning

process based on cost, experience,

and the metallurgy of the entire

system. Successful chemical cleaning

will result in a trouble free startup

and increased life of the boiler,

eliminating the need for major

maintenance.

When chemically cleaning, the

following factors should be

considered:

EQUIPMENT TO BE CLEANED MAY INCLUDE THE FOLLOWING:

• Boiler/economizer

• Condensate/feedwater systems

• Superheater/reheater

• Main steam lines

BEFORE

AFTER

It is essential to consider the metallurgy

in the systems to be cleaned. With new

technologies and the implementation

of exotic metals in today’s superheaters

and high-pressure steam lines,

hazardous waste can be generated and

will ultimately affect the method by

which a proper and safe cleaning should

be conducted. B&W Energy Services will

guide you in making the right choice of

how much to clean and at what cost.

The pre-commissioning of your new

boiler requires a major financial decision.

The company you choose to partner

with at this stage will significantly

impact the future profitability of your

project. B&W Energy Services will walk

you through every step of the process,

ensuring that every measure is taken

to improve productivity and decrease

future expenditures. Our experience in

working on the world’s most complex

pre-commissioning and commissioning

projects makes us the industry’s first

choice in industrial cleaning services.

We invite you to join the ranks of

industry leaders and partner with

B&W Energy Services. Give us a call

and we’ll show you the value of true,

experienced professionals eager to

detail and perform customized solutions

for all your pre-commissioning and

commissioning cleaning needs.

For more information or to engage B&W, contact Chris Oakley at B&W Energy Services by calling281.534.9300, emailing sales@bwenergyservices.comor visit www.bwenergyservices.com.