Boiler Repairs
Steam And Hot Water Boiler Repairs:
ETELAYE SANAT PARS Co. has tried to use standards approved by the Iranian Standards Organization and British Standars (BS2790) to perform all necessary activities on boilers, which in this regard also utilizes expert inspectors of the Ministry of Labor.
Also, the company’s welders have the Iranian standard certificate in the field of boiler welding.
Some other features of the company used in boiler repairs are as follows:
- Use of WPS & PQR in repairs
- Material analysis test on parts and compliance with boiler standard
- Preheating Electrodes
- Performing the necessary inspections
- End-of-work tests (thickness measurement, hydrostatic, weld test and PT)
- Insulation of the body and cementing of boilers
Boiler Repairs:
If your boiler has started making louder noises than usual, or if you see steam and water leaking from it, it may be time for boiler repairs and tube replacement.
Tube replacement in steam and hot water boilers is a very important and specialized task that should be carried out by qualified and experienced boiler repair specialists using standard fire tubes (DIN17175 ST35.8 – EN10217 P235GH) and fire sheets with A516 GR70 – DIN 17175 standard with valid certificates from the manufacturer (MTC) and material analysis and tests performed on tubes and sheets from accredited metallurgical laboratories at the time of tube purchase. In addition, appropriate materials should be used correctly and in accordance with standards in the repair process of steam and hot water boilers. However, restoring the boiler to its former glory can be worth it.
The company that repairs steam boilers and hot water boilers must have qualified welders with welding certificates from standard companies.
Also, the welding repair program for tubes must have a WPS welding standard, and for welding fire tubes, 7018 penetrating electrodes must be used with preheating of the electrode by oven.
It is obvious that if the boiler tubes are replaced by inexperienced people and with inappropriate materials, it can impose very heavy costs on the employer and the operator. It has been observed many times in various projects that boiler repairs have been previously carried out by non-specialist people and have imposed irreparable costs on the employer. In some cases, it has been observed that the main body of the steam boiler shell has been cut, or in the welding of boiler tubes and sheet, penetrating electrodes have not been used, or in the purchase and delivery of boiler wrapper or furnace tubes and networks that have been supplied by the contractor, grade 2 and 3 tubes have been used. low quality and non-fire sheets.
The use of inappropriate materials in the repair of steam and hot water boilers during repairs or a period of 1 to 2 months is not shown. But after a few seasons of operation, the signs of non-standard repairs become apparent. For this reason, it is emphasized that the repair of your boilers must be entrusted to specialized companies with boiler repair standards to prevent very serious life and financial risks.
What is Boiler Tube Replacement?
Boiler retubing is the process of replacing worn fire tubes that are responsible for transferring heat from the burner flame to the water inside the boiler to generate steam or hot water. Boiler fire tubes are subjected to high heat and may be damaged over time due to corrosion, stress, burnout due to improper burner adjustment, or other factors. When boiler fire tubes fail, it can cause water leaks in the boiler, leading to costly repairs in steam and hot water boilers.
How Often Should You Schedule Boiler Repairs?
Several important factors affect the replacement of steam and hot water boiler tubes, including the type of boiler, operating conditions, and water quality. For most industrial boilers, boiler tube replacement is generally scheduled every 5 to 10 years.
5 Signs You Should Repair Your Steam – Hot Water Boiler:
- Tube corrosion: Over time, boiler tubes can corrode and deteriorate. This is especially true if the boiler feed water does not have a softener and deaerator. When a tube corrodes, it can cause water and steam leaks and other problems.
- Leaks: If you notice water or steam leaking from your boiler, it should be inspected by a specialist in steam and hot water boilers. Leaks can be caused by a variety of factors, including corrosion, tube damage, or seal failure.
- Inability to pass the boiler hydrostatic test: All pressure vessels and steam and hot water and hot water boilers must be subjected to annual thickness measurement and hydrostatic testing by qualified inspectors from the labor and standards department. If your boiler fails the hydrostatic test or if part of the body thickness is corroded, it indicates that there is a problem with the device. Hydrostatic tests are required by law and help ensure the safety of boilers for use.
- Efficiency: If your boiler is over 10 years old, it may not be as efficient as it once was. Tube replacement can help improve the efficiency of the device and save you money on your energy bills.
- Safety: Boilers are safe when properly maintained. However, if a tube is damaged or broken, it can create a safety hazard. Tube replacement can help ensure that the steam boiler is safe for use.
Everything You Need for Boiler Repairs:
If you are looking to repair your steam or hot water boiler, ETELAYE SANAT PARS Engineering Company has everything you need for boiler fire tube replacement, boiler tube sheet replacement, boiler main furnace replacement, thickness measurement and hydrostatic tests of steam and hot water boilers, boiler body insulation and sheeting, steam valve repairs, boiler water level and control level updates, boiler control system and switchboard updates, burner service and adjustment, and everything else you need in the field of boilers.
Since 2008, ETELAYE SANAT PARS Engineering Company has been providing its services to various industries such as oil and gas, industrial and automotive companies, food processing, aluminum, hospitals and many more. You can trust our company to provide the tools that are tougher than the job and the best in the industry.
Specialized Boiler Repairs:
- Overhaul and complete overhaul of the boiler (replacement of fire tubes – tubbesheet – furnace and … )
- Steam boiler repair – steam boiler repair – hot water boiler repair – steam boiler descaling
- Reconstruction and renovation of the switchboard including level control components, pressure control, rewiring and …
- Repair of defective parts such as pumps – pressure switches – level gauges – water level gauges and …
- Replacement and modification of body insulation and boiler door masonry
- Periodic repairs and services (acid washing – thickness measurement and … )
- Providing consulting services in the field of purchasing new boilers and replacing parts
- Preparation of technical manuals including electrical and control drawings – spare parts list – preparation of preventive maintenance activities program
Inspection, basic service and annual repair of steam boilers:
- Boiler and its spare parts inspection
- Review of what has been recorded by the operators
- Burner service and repair
- Opening the front door and inspecting and repairing the firebricks as needed
- Closing and sealing the front door of the boiler with a new gasket, if necessary
- Opening the back door and inspecting and repairing the firebricks as needed
- Closing and sealing the back door of the boiler with a new gasket, if necessary
- Cleaning and vacuuming the fire side and flue (breeching)
- Inspection of the water side of the boiler for scale, corrosion and …
- Removing, opening, inspecting and cleaning the lower water level shut-off valve (cut off valve)
- Cleaning the air atomizing system including: source, compressor and …
- Replacing all inspection and manhole valve washers
- Checking the operation of controls, interlocks and settings as needed
- Checking the operation of fans
- Checking the feed water controls
- Lighting the burner and starting the boiler and checking for leaks in the doors if possible
- Checking combustion quality and adjusting it as needed
Boiler failures in various industries cause worrying problems. This is especially true when you are not sure if your boiler can be repaired or needs to be completely replaced. There are many conditions under which your damaged boiler can be repaired quickly and easily without disrupting your industrial workflow.
Boiler Repairs: Everything You Need to Know
Boiler repairs can help you reduce boiler room maintenance and repair costs. However, sometimes boiler failures include: fire tube replacement, rapper sheet replacement, descaling and acid washing, door cementing repair, furnace repair, and more. According to this, the boiler failure problem must first be identified to determine whether boiler repair is sufficient or not. To ensure that the damaged boiler can be reused and repaired, the boiler must be subjected to thickness and hydrostatic tests and inspection by a labor and standards approved expert. In the following, we will discuss the details of specialized boiler repairs.
What are boilers used for?
A boiler is a closed container that transfers heat to water by burning fuel with a burner, and by converting water to steam at a defined pressure, it is transferred to other sections. Boilers are widely used in power plants, paper industries, chemical industries, water treatment plants, textile industries, building materials industries and food industries. Boilers are also used in the tobacco industry, food packaging, refineries, metalworking industries, hospitals, incinerators, printing offices and many others.
In engineering applications, there are different types of boilers such as Fire Tube boilers, Locomotive boilers, Reverse Combustion Chamber boilers, Wet boilers, Dry or Superheated boilers, Water Tube boilers. These boilers are used in various industries such as power plants, paper and chemicals. Currently, various problems (such as scaling, boiler rapper sheet cracking, tube failure and corrosion at high temperatures) related to boilers and their possible solutions are being considered in the field of specialized steel boiler repairs.
Consider safety first in boiler room boiler repairs
When deciding on a steam boiler and boiler repair, always consider safety first. If your boiler is old, it may not comply with modern boiler safety and performance regulations. The first thing you should always do is consult a specialist to make sure your boiler is safe and see if it can be repaired safely.
In the worst cases, your boiler may even be at risk of producing carbon monoxide. A boiler room boiler repair specialist and, in general, a boiler repairman can inform you whether your boiler can be used with repairs and in some cases by capping the boiler fire tubes to solve the problems caused by boiler water leakage or needs to replace the boiler fire tubes and in some cases replace the boiler rapper sheet. Once your boiler has been checked and you are sure it is safe to use, you can consider other factors that affect boiler repair or replacement.
ETELAYE SANAT PARS Engineering Company is ready to send a labor and standards approved expert to evaluate the possibility of continued operation of your various steam boilers, hot water boilers and hot oil boilers to review and perform thickness and hydrostatic tests of various hot water boilers, steam boilers, and hot oil boilers at your project site to determine the full extent of boiler failures and then inform the customer of the boiler repair and continued operation approval.
Boiler Repairs: Should You Repair or Replace Your Boiler?
Can you save money on boiler repairs?
Even if your boiler malfunction is fixed, a new boiler may be significantly more energy-consuming and gas-consuming due to the changes that have occurred in the burner. In order to prevent failures that may occur with the continued operation of the burner and also for burner service, burner flame adjustment and also to reduce fuel consumption and increase burner efficiency, you can contact us.
Boiler repairs can also be effective in many cases. If your boiler is a modern and energy-efficient model, having it repaired by a registered specialist company may be the best way to quickly restore the boiler to normal operation.
How much does it cost to repair a boiler?
For some old boilers, the cost of boiler repairs may increase significantly because replacement parts are no longer readily available. Review the potential cost of repairing your boiler and evaluate whether replacing it may be a more cost-effective solution. Remember that the cost of repairing an old boiler increases over time.
If the cost of repairing your boiler repair is relatively low or the repair is simple, repair may be the best choice for your boiler. Most of the failures in steel boilers are related to the failure of the boiler fire tubes and the failure of the front and rear sheets of the boiler, which can be solved by replacing them. In some cases, boiler failures are related to damage to the masoned parts of the boiler door, failures and spills of the boiler furnace refractory cement, which can be resolved with the help of a boiler room boiler repair specialist.
Many new boilers also come with a warranty. This can cover the cost of replacement parts and may even cover labor costs in some cases.
How frequent are boiler failures?
Has your boiler malfunction become very frequent? If your boiler is constantly having problems, you should first monitor the boiler maintenance. Check for the presence of a water softener in the boiler room and make sure it is working properly and check the PH of the water entering the boiler. Check for the presence of a steam deaerator and make sure it is working properly. The most important issue is the periodic service and adjustment of the burner. By servicing and adjusting the burner in time, many of the failures and damage to the boiler fire tubes and furnace can be prevented. Certainly, by observing the mentioned cases, many boiler failures can be prevented.
As a last resort, replacing it with a new model may be the best option. The cost of boiler repairs and ongoing maintenance and boiler repairs can increase over time, especially for old boilers.
Frequent breakdowns can be troublesome. Think about whether you prefer to avoid boiler reliability and replace your boiler with a new model that is likely to require much less maintenance. If your boiler rarely breaks down and is a newer model, repairing it is probably the best approach as recurring problems are unlikely.
In many cases, , hot water boiler repair, steam boiler repairs, fire tube replacement and rapper sheet replacement is the most cost-effective and efficient way to get your heating back up and running.
If you have a newer boiler that is more reliable, your boiler is unlikely to need replacing. However, if your boiler is old, without a warranty, or even potentially dangerous, you should consider replacing it with a new model. In any case, always consult with a professional and experienced company in the field of specialized boiler repairs that can recommend the best solution to you and help you weigh your options.
Our company, based on the technical knowledge and experience of its experts, is ready to provide services to customers in the field of services including: overhaul and service of steam and hot water boilers, hot oil, acid washing and descaling of boilers, replacement of fire tubes, masonry in boilers, leak detection and welding tubesheet of all types of hot water, steam and hot oil boilers Pakman, Mashinsazi Arak, Super Active, Tahvie danan Tehran and …