Boiler Equipment Maintenance Plans

We offer a customizable Boiler Equipment Maintenance Plan to maintain optimum performance, improve system stability, extend equipment life, and minimize risk of a boiler system failure. By participating in the contracted service, your equipment will receive the necessary assessments, testing, and maintenance to fully support the routine and essential inspections. Ultimately, these services will enhance equipment safety, efficiency, and performance. At the end of the annual maintenance, the boiler will be closed and fitted with new high-quality gaskets. All findings will be properly documented.

Customize Your Maintenance Visit Schedule

To accommodate your operational needs and availability, you can customize the frequency of on-site visits to be Annual, Semi-Annual, Quarterly, or Monthly. Each option entails different inspections and services associated with each visit, see what’s included in each plan below.

MONTHLY MAINTENANCE PLAN

The Maximum Coverage option where preventive maintenance will be performed every month. The inspections and tests listed below will be completed eight (8) times a year in addition to one (1) Annual Maintenance visit and three (3) Quarterly Maintenance visits.

Combustion and Controls

Inspect all actuators & motors for abnormal operation
Inspect atomizing media equipment
Inspect boiler & burner components for wear
Inspect burner flame pattern
Inspect firing rate control
Inspect flue, vent, stack, & outlet dampers
Inspect fuel train(s), regulator(s), & valves
Inspect gauges, monitors, & indicators
Inspect inlet & outlet dampers
Inspect instruments & equipment settings
Inspect linkage, drive arms, & damper connections for wear
Inspect pilot & main fuel flame signal strength
Inspect pilot line, regulators, & valves
Inspect the blower motor operations
Test & reset combustion
(Optional) Secondary fuel tune-up

Fireside

Inspect boiler for visible signs of hot spots & discoloration

Waterside

Blow down the gauge glass assembly
Inspect the safety relief valves for leakage
Inspect the feed water valve & controls for operation
Inspect water column & gauge glass for wear & etching
Test water column water level ports

QUARTERLY MAINTENANCE PLAN

The Principal Coverage option where preventive maintenance will be performed on a quarterly basis. The inspections and tests listed below will be completed three (3) times a year in addition to one (1) Annual Maintenance visit. The same features are also available with the Semi-Annual Maintenance option, but with less scheduled visits.

Combustion and Controls

Inspect all actuators & motors for abnormal operation
Inspect all lights, indicators, & alarms for functionality
Inspect atomizing media equipment
Inspect boiler & burner components for wear
Inspect burner flame pattern
Inspect firing rate control
Inspect flue, vent, stack, & outlet dampers
Inspect fuel train(s), regulator(s), & valves
Inspect gauges, monitors, & indicators
Inspect igniter for damage & wear
Inspect inlet & outlet dampers
Inspect instruments & equipment settings
Inspect linkage, drive arms, & damper connections for wear
Inspect pilot & main fuel flame signal strength
Inspect pilot line, regulators, & valves
Inspect the blower motor operations
Perform a pilot turndown test
Perform leak test on pilot & fuel train(s)
Test & reset combustion
Test flame failure detection system for pilot & main fuel(s)
(Optional) Secondary fuel tune-up

Fireside

Inspect boiler for visible signs of hot spots & discoloration

Waterside

Blow down the gauge glass assembly
Inspect blowdown valves & equipment for leakage & wear
Inspect the safety relief valves for leakage
Inspect the feed water valve & controls for operation
Inspect water column & gauge glass for wear & etching
Test water column water level ports
Perform a slow drain test on low water cutoff

SEMI-ANNUAL MAINTENANCE PLAN

The Adjusted Principal Coverage option where preventive maintenance will be performed on a semi-annual basis. The inspections and tests listed below will be completed two (2) times a year. The same features are also available with the Quarterly Maintenance option, but with more scheduled visits.

Combustion and Controls

Inspect all actuators & motors for abnormal operation
Inspect all lights, indicators, & alarms for functionality
Inspect atomizing media equipment
Inspect boiler & burner components for wear
Inspect burner flame pattern
Inspect firing rate control
Inspect flue, vent, stack, & outlet dampers
Inspect fuel train(s), regulator(s), & valves
Inspect gauges, monitors, & indicators
Inspect igniter for damage & wear
Inspect inlet & outlet dampers
Inspect instruments & equipment settings
Inspect linkage, drive arms, & damper connections for wear
Inspect pilot & main fuel flame signal strength
Inspect pilot line, regulators, & valves
Inspect the blower motor operations
Perform a pilot turndown test
Perform leak test on pilot & fuel train(s)
Test & reset combustion
Test flame failure detection system for pilot & main fuel(s)
(Optional) Secondary fuel tune-up

Fireside

Inspect boiler for visible signs of hot spots & discoloration

Waterside

Blow down the gauge glass assembly
Inspect blowdown valves & equipment for leakage & wear
Inspect the safety relief valves for leakage
Inspect the feed water valve & controls for operation
Inspect water column & gauge glass for wear & etching
Test water column water level ports
Perform a slow drain test on low water cutoff

ANNUAL MAINTENANCE PLAN

The Core Coverage option where preventive maintenance will be performed on a semi-annual basis. The inspections and tests listed below will be completed once a year.

Combustion and Controls

Inspect all actuators & motors for abnormal operation
Inspect all lights, indicators, & alarms for functionality
Inspect & clean all burner traps & strainers
Inspect atomizing media equipment
Inspect boiler & burner components for wear Inspect burner flame pattern
Inspect firing rate control
Inspect flue, vent, stack, & outlet dampers
Inspect fuel nozzles & fuel outlet orifices
Inspect fuel train(s), regulator(s), & valves
Inspect diffuser positioning
Perform a pilot turndown test
Perform leak test on pilot & fuel train(s)
Test & reset combustion
Test & verify firing rate control set points
Test flame failure safety shutdown timing
Test fuel train(s) interlocks
Test high & low fuel temperature/pressure interlocks
Inspect gauges, monitors, & indicators
Inspect igniter for damage & wear
Inspect inlet & outlet dampers
Inspect instruments & equipment settings
Inspect linkage, drive arms, & damper connections for wear
Inspect main fuel safety shutoff & vent valves for leakage
Inspect pilot & main fuel flame signal strength
Inspect pilot line, regulators, & valves
Inspect the blower motor operation
Inspect the diffuser & burner components for ear
Test atomizing medium interlocks & set points
Test burner position interlocks
Test combustion air proving switch
Test damper position interlocks
Test flame failure detection system for pilot & main fuel(s)
Test operating & high limit control functionality
Test trial for ignitions & full sequence timing
(Optional) Secondary fuel tune-up

Fireside

Inspect boiler for visible signs of hot spots & discoloration
Inspect attaching mechanisms & open all access doors
Inspect fireside of boiler & clean debris or soot as required
Inspect the refractory & insulation for wear

Waterside

Drain boiler, open manholes & handholes for inspection
Inspect & flush waterside of boiler
Inspect PV for cracks, visible corrosion & scale
Inspect the feed water valve & controls for operation
Open & inspect internals of low water cutoff equipment
Test safety relief valves for proper operation (as requested) Blow down the gauge glass assembly
Inspect & flush pressure control tree as needed
Inspect blowdown valves & equipment for leakage & wear
Inspect the safety relief valves for leakage
Inspect water column & gauge glass for wear & etching
Perform a slow drain test on low water cutoff
Test water column water level ports Terms of Plan Membership

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Membership Term Options

In addition to offering customizable options for the frequency of maintenance services, we also provide the ability to select the corresponding term duration, indicating the length of the membership contract. We’ve divided these options into four (4) tiers, each one coming with complimentary benefits added to the extended length.

FIVE YEAR MEMBERSHIP TERM

Recurring services and inspections for five years. Term benefits include:

Fixed labor rate for three (3) years
15% discount on parts for any equipment
Two (2) free training classes at a local seminar
Priority scheduling benefits

THREE YEAR MEMBERSHIP TERM

Recurring services and inspections for three years. Term benefits include:

Fixed labor rate for two (2) years
10% discount on parts for contracted equipment
One (1) free training classes at a local seminar
Priority scheduling benefits

TWO YEAR MEMBERSHIP TERM

Recurring services and inspections for two years. Term benefits include:

Fixed labor rate for two (2) years
5% discount on parts for contracted equipment
Priority scheduling benefits

ONE YEAR MEMBERSHIP TERM

Selected services and inspections for one year. Term benefits include:

5% discount on parts for contracted equipment
Priority scheduling benefits

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Why Should You Invest?

Routine Boiler and Pressure Vessel inspections are required by local jurisdictions. Typically, these critical inspections are required annually, but in some rare cases, they can be required bi-annually. The inspection frequency is determined by local laws and regulations. As such, Boiler and Pressure Vessel inspections are unavoidable and will result in a boiler and/or boiler system to be temporarily taken offline. The specific details involved to perform an annual inspection can be overwhelming for companies that do not have the resources to stay current with changing compliance regulations. As a result, it is beneficial and very common for companies to engage in knowledgeable technical resources who can easily navigate the inspection process. Outsourcing this responsibility to trained technicians can facilitate an expedient and successful approval by the local jurisdiction while enhancing your preventive maintenance objectives.

Under the Equipment Maintenance Plan, you can—

Improve operational stability
Improve burner combustion efficiency
Improve boiler heat transfer efficiency
Enhance safety and issue identification
Reduce long-term repair cost
Discounted parts quotes where needed
Fixed labor erase inconvenience service fees
Reduce annual inspection difficulties
Priority access to technical expertise & service support
Priority access to R.F. MacDonald Co. parts inventory
Single-source responsibility for boiler system support
Extend equipment life

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Maintaining Your Equipment

Whether or not you choose to utilize our preventive maintenance program, we highly recommend that you take steps to insure that your boiler equipment is protected. Additionally, we offer credited training courses on boiler operations and mechanics, visit R.F. MacDonald Co. Training for more information. Below are some valuable tips to follow when being proactive on the condition of your boiler application.

Controls
Proper water levels, operating pressures, and control devices are critical to your boiler system’s performance. Carefully check gauge glass for cracks or erosion and inspect the float and switches. Check the operation of all limit switches and sequences of operation timing.

Burners
Remove, check and clean dampers, nozzles, electrodes, scanners, hoses, compressors, filters, diffusers, etc. for blockage and/or damage.

Refractory
Check for cracking. Unrepaired, even mirror cracks can reduce boiler efficiency and allow warping and damage to occur on vital metal surfaces.

Fireside
Clean out any detectable soot can reduce the efficiency of your boiler tubes, tube sheets, and furnace area. Replace fireside gaskets when closing the boiler.

Waterside
Drain, open and flush the entire waterside of the boiler. Remove all low water controls to clean and inspect piping. Flush makeup and/or feed water pump strainers and water column float chambers. Drain expansion tanks and remove all plugs in control piping. Inspect and re-install controls. Inspect for damage due to waterside leakage around handholes and manholes, gauge glass assemblies and other wet surfaces. Check gaskets for wear and tear.