It is currently Mon Jan 22, 2018 12:00 am Advanced search

Boiler repair

Stick Welding Tips, Certification tests, machines, projects

Boiler repair

Postby Poland308 » Sun Jan 07, 2018 2:14 pm

23D61126-3114-4EB1-8031-C1AAEAC5A942.jpeg
23D61126-3114-4EB1-8031-C1AAEAC5A942.jpeg (46.69 KiB) Viewed 110 times
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.
Attachments
1EE6A329-75EA-4242-BB91-70E5695D9E8D.jpeg
1EE6A329-75EA-4242-BB91-70E5695D9E8D.jpeg (51.97 KiB) Viewed 110 times
D99D4869-E6AD-445F-B4D3-01803F635B4E.jpeg
D99D4869-E6AD-445F-B4D3-01803F635B4E.jpeg (48.63 KiB) Viewed 110 times
I have more questions than answers

Josh
Poland308
Weldmonger
 
Posts: 2378
Joined: Thu Sep 10, 2015 8:45 pm
Location: Iowa

Re: Boiler repair

Postby Poland308 » Sun Jan 07, 2018 2:17 pm

22285EF0-3034-4444-ACA0-8EAB96A857EC.jpeg
22285EF0-3034-4444-ACA0-8EAB96A857EC.jpeg (46.46 KiB) Viewed 103 times

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.
Attachments
5C3EEFB2-55AF-4E29-A36C-95A666E87228.jpeg
5C3EEFB2-55AF-4E29-A36C-95A666E87228.jpeg (56.6 KiB) Viewed 103 times
I have more questions than answers

Josh
Poland308
Weldmonger
 
Posts: 2378
Joined: Thu Sep 10, 2015 8:45 pm
Location: Iowa

Re: Boiler repair

Postby Poland308 » Sun Jan 07, 2018 2:28 pm

223215D1-C0AD-48EF-BD62-282F94D9CE64.jpeg
223215D1-C0AD-48EF-BD62-282F94D9CE64.jpeg (64.71 KiB) Viewed 101 times

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.
Attachments
523687B9-2E40-439F-B9F8-AECCE5CB0FB6.jpeg
523687B9-2E40-439F-B9F8-AECCE5CB0FB6.jpeg (60.21 KiB) Viewed 101 times
F3D046A7-D11B-4A44-B63B-FF6346FE744F.jpeg
F3D046A7-D11B-4A44-B63B-FF6346FE744F.jpeg (70.5 KiB) Viewed 101 times
D9152249-6734-4FD2-B46A-DDECDA241EE8.jpeg
D9152249-6734-4FD2-B46A-DDECDA241EE8.jpeg (70.46 KiB) Viewed 101 times
2D4B7A00-E226-48CC-91DD-3783916B86CB.jpeg
2D4B7A00-E226-48CC-91DD-3783916B86CB.jpeg (70.46 KiB) Viewed 101 times
32601DE7-6938-4516-8B8B-E9D3DE8AEFAA.jpeg
32601DE7-6938-4516-8B8B-E9D3DE8AEFAA.jpeg (61.49 KiB) Viewed 101 times
I have more questions than answers

Josh
Poland308
Weldmonger
 
Posts: 2378
Joined: Thu Sep 10, 2015 8:45 pm
Location: Iowa

Re: Boiler repair

Postby Poland308 » Sun Jan 07, 2018 2:32 pm

5A1473AC-BBA4-4C44-8A6F-3EBDAD1BBAE0.jpeg
5A1473AC-BBA4-4C44-8A6F-3EBDAD1BBAE0.jpeg (44.89 KiB) Viewed 99 times

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.
Attachments
278BC3DF-CD46-4393-AD79-3B1ECD2B75B8.jpeg
278BC3DF-CD46-4393-AD79-3B1ECD2B75B8.jpeg (51.38 KiB) Viewed 99 times
415700C2-6FED-4FAA-B688-2799B63516BC.jpeg
415700C2-6FED-4FAA-B688-2799B63516BC.jpeg (54.07 KiB) Viewed 99 times
I have more questions than answers

Josh
Poland308
Weldmonger
 
Posts: 2378
Joined: Thu Sep 10, 2015 8:45 pm
Location: Iowa

Re: Boiler repair

Postby Coldman » Sun Jan 07, 2018 3:45 pm

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.


Sent using Tapatalk
Flat out like a lizard drinkin'
Coldman
Weldmonger
 
Posts: 1131
Joined: Mon Dec 15, 2014 2:16 am
Location: Oz

Re: Boiler repair

Postby Poland308 » Sun Jan 07, 2018 4:54 pm

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.
I have more questions than answers

Josh
Poland308
Weldmonger
 
Posts: 2378
Joined: Thu Sep 10, 2015 8:45 pm
Location: Iowa


Return to Stick Welding/Arc Welding - Shielded Metal Arc Welding