Essential Welding Repairs for Durability

Not all welding services are created equal. Some professional welders focus on aesthetics, but serious commercial and industrial welders know that durability is the most important factor to consider. This is exceptionally true when it comes to pressure vessels like boilers and chillers, where a weld failure could have disastrous consequences. Read on to find out about some of the most essential welding repairs for durability and equipment safety.

Leaks in Boiler Tubes

Stopping leaks in boiler tubes is one of the most common types of welding repair services undertaken by industrial welders. Since these leaks occur inside the boiler, they're notoriously difficult to find. They're typically recognized by the puddle beneath the equipment or an increased flow in the feedwater. To fix this problem, a professional repair technician will inspect all of the boiler tubes looking for scaling, pitting, and weld defects. The affected tubes will then be removed, and new ones will be installed. Once the new tubes are welded into place, hydro-testing can confirm the success of the repairs.

Piping Leaks

Piping leaks are most common where the pipes connect to valves or equipment. They tend to be less serious than boiler tube leaks but should still be addressed quickly, as valves are the top source of steam leaks, and just one leaky valve can cost a company thousands of dollars per year. If this is the case, the valve will need to be removed and a new one will need to be fitted. If the leak occurs elsewhere in the piping, the chances are good that it will be a pinhole leak. A certified welder should be able to fix the leak quickly and easily. However, if the affected pipe is otherwise damaged or severely worn, it may need to be removed and a new one welded into place.

Cracked Tube Sheets

Cracked tube sheets in boilers, gas/steam heat exchangers, and other pressure vessels are often stress corrosion cracks. Repairing these cracks requires removing the defective welds and replacing them. Post-weld heat treatment may also be necessary, and tube-to-tube sheet joints will need to be sealed using tube expansion. Like all welding repairs to pressure vessels, this procedure can only be performed safely by a welding team that is "R" Stamp certified and meets all legal ASME requirements. Failing to find a certified welder can lead to trouble down the line in the form of additional cracks and weld failures.

When to Call for Emergency Repairs

Some types of pressure vessel repairs can wait until the next scheduled inspection when the boiler will already be offline. However, there are some circumstances where the only appropriate solution is to call for emergency repairs. If a leak is substantial, there's a chance that the pipe or tube that's cracked or otherwise damaged could burst. The safest thing to do is to call to schedule welding repairs any time that a leak becomes apparent.

The Importance of Hiring the Right Welders

Not all welders are capable of performing repairs to boilers and other pressure vessels. Facility managers need to find welding teams that are R-Stamp certified to ensure that the repair gets done right. This certification is issued to capable fabricators who meet code requirements by the National Board of Boiler and Pressure Vessel Inspectors. Welders who don't have it won't be able to guarantee an effective repair, which can lead to safety issues.