BOILERS are inarguably one of the most critical assets in a process plant. They often play an essential role in several downstream processes. They frequently represent 30-50% of a plant’s energy usage. Understandably, managers must ensure that they are well maintained and regularly inspected, running both efficiently and reliably.
Certain aspects of boiler technology have advanced substantially in recent decades. Adoption has been fairly rapid in residential and commercial applications, where it is both economically sensible and physically feasible to replace the entire boiler rather than repairing the existing one, which may not even an option for many lighter-duty class boilers.
On the other hand, adoption of new technologies has been much slower in the industrial process sector. In the USA, roughly half of the boilers in service are more than 25 years old. We regularly see boilers that are 50+ years old, running on antiquated or obsolete components.