475 Inside the Boiler: Inspection, Failure Analysis, and Photography with Cheryl Heiser

A boiler failure can create pressure quickly: production is down, emotions are high, and the water treater may be the first person blamed. Cheryl Heiser of TGWT Clean Technologies Inc. joins Trace Blackmore, CWT, to walk through a more disciplined way to evaluate boiler issues by looking beyond chemistry alone.     Why Boiler Failures Need a Broader Lens  Cheryl brings field experience from the OEM boiler side, conventional water treatment, and purified tannin boiler treatment. Her perspective is rooted in the idea that no two boilers are the same. Design, operating conditions, fuel, history, circulation, steam separation, and customer practices all influence how a boiler behaves.  She explains the premise of her AWT paper: helping water treaters avoid being immediately blamed when boiler tube failures occur. In her case study, two twin HRSG units were producing 100,000 pounds per hour of steam each, with superheaters operating at 600 PSI and 750 degrees Fahrenheit. The failures did not point to a simple water treatment explanation. Instead, the investigation involved steam drum internals, carryover, tube geometry, circulation concerns, and normal operating water level.    What to Look for Inside the Boiler  Cheryl emphasizes inspection discipline. Take photos, use a borescope when available, enter the boiler when safe and possible, and look for patterns in deposits, discoloration, distortion, turbulence, uneven circulation, and steam drum staining. She also explains why orientation matters. A photo that makes sense during the inspection may be difficult to interpret later unless the location and direction are clearly identified.  Deposit analysis and metallurgical analysis can also help determine whether a failure is connected to deposits, material factors, overheating, combustion-side issues, or other mechanical contributors. The key is to understand the boiler as a system, not as a black box.    Trust, Documentation, and Customer Communication  When a boiler is down, the relationship with the customer matters as much as the technical investigation. Cheryl encourages water professionals to guide customers toward an investigative approach instead of a defensive reaction. That means asking better questions, understanding what relies on the steam, knowing the customer's priorities, and reassuring them that the goal is to find the root cause.  Trace closes the conversation by reinforcing the importance of documentation. Service reports protect the customer, the boiler, and the water treater. When recommendations are made, they need to be written down, repeated when necessary, and tied back to the operational risks they are meant to prevent.  Listen to the full conversation above. Explore related episodes below. Stay engaged, keep learning, and continue scaling up y