Repair and maintenance
Boiler repair and maintenance
Tube leaks, worn pressure parts and planned upkeep, found, repaired and proven, so the boiler returns to service with its records up to date.
Working principle
How it works
The working process in four steps.
Find what failed
Inspection locates leaks, thinning and erosion.
Cut out the damage
Failed tube lengths are removed back to sound material.
Weld in new material
Replacement parts go in with traced material and qualified welders.
Prove it before firing
NDT and a pressure test confirm the repair.
Process flow chart
From order to hand-over
Diamonds are hold points: work stops until the check is signed.
- IsolationBoiler cooled and made safeHold point
- InspectionVisual and thickness survey
- Repair scopeAgreed list and approvalHold point
- Cut outRemove damaged parts
- ReplaceNew material welded in
- NDTOn repair weldsHold point
- Hydro testPressure provenHold point
- Return to serviceReport handed over
3D model
Where boilers wear, in 3D
Drag to turn it. Labels name the parts we make, fit and test.
ER diagram
How every record connects
One enquiry links through to its quotation, order, jobs, inspections and dispatch, so nothing gets lost between teams.
Quality assurance plan
What gets checked
A typical plan, agreed with you for each job.
| Stage | Check | Method | Record | Role |
|---|---|---|---|---|
Before work | Isolation and permits | Permit check | Work permit | H |
Survey | Tube thickness and hardness | UT gauging and hardness test | Thickness report | R |
Root cause | Why the tube failed | Failure inspection | Root cause report | R |
Material | Grade matched to original | Test certificate | Material register | R |
Repair welds | Soundness | RT or DPT | NDT report | H |
Final | No leak at test pressure | Hydro test | Test certificate | H |
H: hold point, work stops until signed. W: witnessed. R: record reviewed.
Parts and rates
Parts and indicative rates
Indicative market rates. Your written quotation sets the final price.
| Part or service | Specification | Indicative rate |
|---|---|---|
Boiler tube, seamless | SA 210 Gr A1 | ₹85 to ₹170 per kg |
Boiler safety valve | Spring or dead weight, by size | ₹9,000 to ₹14,000 per piece |
Water level gauge | Tubular to reflex, by pressure | ₹2,000 to ₹14,000 per piece |
Tube leak repair | Per visit, by access | On quotation |
Boiler retubing | Bank and water-wall tubes | On quotation |
Boiler modification | Capacity or fuel change | On quotation |
Root cause analysis | Tube failure report | On quotation |
Annual maintenance contract | Planned visits | On quotation |
Bulk orders
A 45% advance confirms your order
- Purchase orderSend your PO with the 45% advance.
- Slot confirmedProduction and the delivery date are fixed.
- Balance and dispatchThe balance follows your quotation's terms.
Rates are before GST and freight. Only your written quotation fixes the price.
Documents
What you receive
Documents on a typical job. Statutory approvals depend on the job and are agreed in the quotation.
- Inspection and thickness reportReport
- Root cause reportReport
- Repair scope and approvalApproval
- Material test certificatesCertificate
- Welder recordsRecord
- NDT reportsReport
- Hydro test certificateCertificate
Enquiry
Ask about boiler repair
Share the work, the plant and your timeline. You will receive a written quotation.