FAQ & Resources

Control system maintenance is an often neglected part of boiler house operations. As with all maintenance functions, regularly scheduled inspections and functional verification of your boiler control and burner management systems can help prevent service interruptions and safety hazards. In addition to being good practice, this is also a requirement for compliance with NFPA boiler safety codes, which state that "a program shall be provided for inspection and maintenance of equipment at intervals consistent with the type of equipment used, service requirements, and manufacturer's recommendations". Many facilities will have regularly scheduled calibration programs for individual switches and sensors, but even these programs may fall short of the need to verify and document burner management system functionality.

A leaking steam trap or other component can cost you plenty. Placing a dollar number on a failed steam trap can be a real surprise. For a typical boiler room generating 150 psig steam, a value of $7.50 per thousand pounds of steam would be a reasonable estimate. On a 150 psig header, a single steam trap stuck open with a trap orifice of 1/8th inch generates an estimated steam loss of 75.8 pounds per hour. At 8,760 hours per year of operation, fixing this trap would generate annual savings of $4,980!

Follow up question: When was the last time your facility followed through on a steam trap testing program?

Monitoring boiler performance on an annual basis is one of the most basic steps towards evaluating and maintaining good combustion efficiency. Many combustion tuning reports fall short of this goal by recording and evaluating only a few variables each year. Combustion efficiency is based on boiler exhaust or stack temperature and flue gas oxygen concentrations, and is a good indicator of how effectively the heat content of the fuel is being utilized by the boiler system. For a typical 150 psig boiler operating throughout the year at 45,000 pound per hour steam loads, a 2% improvement in combustion efficiency could generate fuel savings on the order of $100,000 per year. If you don't know what your baseline is, you could be sending money straight out the stack.
Follow up question: Do your annual boiler tuning reports include combustion efficiency?

The formation of boiler scale can result in a substantial increase in energy costs. Using guidelines established by the DOE, formation of scale as little as 1/32 of an inch can result in a fuel loss of 2%. The best defense against scale is a good offense; maintain quality boiler makeup water, proper boiler chemistry, and adequate boiler blowdown. Taking the time to perform annual boiler tune-ups and maintain quality tuning documentation also helps - an indirect indicator of scale is boiler flue gas temperature. Check your records for changes in flue gas temperature and combustion efficiency with boiler load and excess air held constant; these would be an indirect indicator of scale formation.

ASME Code certification authorizes a fabricator to stamp pressure vessels and boilers, certifying they meet national safety standards for design, welding, and inspection. Only ASME-certified shops can legally build equipment for applications where failure risks catastrophic injury or property damage. The stamp demonstrates third-party auditing of procedures, welder qualifications, and quality systems-required for insurance, permitting, and regulatory compliance in industrial facilities.

Troy Boiler Works fabricates with carbon steel, stainless steel, nickel alloys, and specialty metals engineered for high-pressure and high-temperature applications. Material selection depends on operating pressure, temperature range, corrosive environment, and code requirements. Stainless and nickel alloys handle corrosive fluids and extreme heat where carbon steel would fail prematurely.

The shop handles both custom one-off fabrications and production runs, provided the project meets ASME Code requirements or industrial-grade specifications. Minimum scope depends on engineering complexity and material procurement-small pressure vessels and specialized components are routinely fabricated alongside larger boiler systems. Projects requiring certified welding, code compliance, or engineered drawings fit the shop's capabilities regardless of size.

Pressure vessels operating above 15 PSI and exceeding six-inch diameter, or containing hazardous fluids at any pressure, typically require ASME certification under state and insurance regulations. Certification ensures the vessel withstands rated pressure without rupture and meets inspection and testing standards. Facilities subject to OSHA, EPA, or state boiler inspections mandate ASME-stamped vessels for liability and permitting.

Repair addresses specific failures-tube leaks, refractory damage, control malfunctions-while the boiler structure and major components remain serviceable. Replacement becomes necessary when pressure boundaries corrode beyond safe repair limits, efficiency drops significantly due to scale buildup and age, or code changes make the existing unit non-compliant. Boilers over 25 years old with repeated tube failures often cost more to maintain than replace.

Visible signs include water leaks around seams or tube connections, pressure fluctuations during operation, unusual noises like kettling or banging, and efficiency loss reflected in higher fuel consumption. Most jurisdictions require annual inspections for commercial and industrial boilers regardless of condition. Corrosion, scale buildup, and refractory cracks develop gradually and aren't always obvious until failure occurs.

Material type, wall thickness, code requirements, and welding complexity drive fabrication costs. Stainless steel and nickel alloys cost significantly more than carbon steel, while exotic metals require specialized welding procedures and additional testing. ASME Code compliance adds engineering, documentation, and third-party inspection costs that non-code vessels avoid.

Code-certified welders have passed qualification tests proving they can produce welds that meet strength, penetration, and defect standards required for pressure-retaining equipment. Welds on boilers and pressure vessels must withstand cyclic stress, thermal expansion, and internal pressure without cracking. Uncertified welds can't be legally stamped or inspected under ASME Code, making the equipment uninsurable and non-compliant.

Engineering review confirms design calculations, material specifications, and code compliance before fabrication begins. Steel is cut, formed, and welded per approved drawings, then pressure-tested and inspected by authorized third parties. The completed boiler receives ASME Code stamps and documentation required for installation permitting and insurance approval.

Wall thickness determines maximum allowable working pressure-the higher the operating pressure, the thicker the material required to prevent rupture. Thickness calculations also account for corrosion allowance, joint efficiency, and temperature effects on material strength. Under-sizing wall thickness risks catastrophic failure, while over-sizing adds unnecessary weight and material cost.