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Here are a few things to look for and how to address it proactively:
LOOK FOR: Increasing fuel bills without changes in production
If fuel costs rise despite steady production rate, your system is consuming excess fuel.
THE FIX: Perform regular burner tuning to ensure optimal fuel-air ratio. Misaligned burners significantly increase fuel consumption. Proper adjustments can reduce energy usage by 10–20%.
LOOK FOR: System takes longer to reach operating temperature
Extended heat-up times indicate heat loss or reduced efficiency.
THE FIX: Inspect heat exchanger media for clogging or wear. Dirty or worn media reduces heat recovery, increasing fuel use. Replacing degraded media restores efficiency.
LOOK FOR: Frequent Cycling (Excessive On/Off)
Frequent cycling leads to energy waste and premature wear.
THE FIX: Evaluate temperature sensors and pressure control systems. Frequent cycling often indicates sensor malfunction or improper bypass valve settings.
LOOK FOR: Increased component replacements (dampers, poppet valves, gaskets)
Repeated replacements usually point to underlying mechanical issues.
THE FIX: Regular calibration, vibration analysis, and airflow balancing can prevent premature wear and component failure.
LOOK FOR: More unscheduled maintenance and breakdowns
Frequent breakdowns reflect insufficient maintenance.
THE FIX: Establish a structured Preventative Maintenance Plan with scheduled inspections, component servicing, and regular system audits to proactively address potential problems.
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