PROBLEM

AmerCable was operating a 45-year-old Cleaver-Brooks fire tube boiler that had developed significant internal failures. The unit had 18 cracked tubes with rapid deterioration in the lower section, along with 9 previously plugged tubes that were also failing. Additionally, the main gas burner was damaged.

Due to code limitations, no additional tubes could be plugged without compromising safety and compliance, leaving the boiler at risk of failure and unable to pass inspection—jeopardizing critical steam production for their operations.

SOLUTION

Storer Services performed a full diagnostic and executed a comprehensive repair strategy to restore the boiler. The team removed all 98 existing tubes, inspected the tube sheet for critical tolerance, and installed 98 new tubes.

Each tube was precision steel welded on both the front and rear to ensure long-term integrity. The main gas burner was also rebuilt to restore proper combustion performance.

Once repairs were completed, the boiler underwent hydrostatic testing at 250 PSI for 10 minutes, successfully passing inspection. Final safety checks were performed, and the boiler was carefully pre-heated and returned to full operating pressure.

LEGACY

The project restored the boiler to safe, reliable operation while extending its service life and avoiding the need for immediate replacement. Storer Services completed the entire repair in under three weeks, exceeding client expectations and minimizing operational disruption.

AmerCable continues to rely on Storer for routine boiler maintenance and support, ensuring consistent steam production for their process needs and long-term equipment reliability.