Welding Tips and Tricks

Probably going to take me a while to post the pictures.These boiler tubes are tapered and driven into the lower tube. Between each set of tubes, top and bottom, is a stud that’s welded on, and then there’s a clip that is like a square washer that bolts down against the lip as a safety retainer.

This boiler was run with too low of a water temp, causing condensation of the flue gas, creating carbonic acid. Causing severe corrosion of all the lower studs.

Had to cut off all the lowers on both sides 84 per side, and welded on new ones. Since it’s welded to the lower tube it falls under pressure vessel code repair.

Filled it back up and did a preliminary pressure test at 90 psi. Have to bring back a hydro pump and the certified gauge for a final pressure test at 120psi on Monday for the inspector.

Great job! Boiler is saved. Dirty deeds done dirt cheap compared to a new boiler.
I take it replacement tubes were available so you didn’t have to bend them up.


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Fortunately the boiler manufacturer is only a couple of states away and still in business. They fabricated the tubes specifically for that boiler. There’s another one identical to it, right next to it, that’s probably going to get done in a month or two.