Boiler Reconditioning Process
Every reconditioned, used boiler Powerhouse sells includes a rigorous twenty-eight point inspection process. Rest assured that whether it is a massive Cleaver Brooks boiler or a 50 hp Fulton boiler, you are buying a product that meets our stringent Certification Process and the quality of the boiler is back to “like new” condition.
POWERHOUSE 28-POINT RECONDITIONING PROCEDURE
Every Reconditioned Boiler comes with Complete 1-Year Parts Warranty
- Identify any missing external components
- Assess the condition of casing and insulation
- Internal Inspection
- Identify any missing internal components
- Assess the condition of the mechanical trim
- Test working operation of mechanical valves
All tests performed by experienced boiler makers and service technicians who have inspected hundreds of boilers.
- Open the front and rear doors
- Open all handholes and manways
- Inspect tubes, fireside, and waterside
- Inspect the tubesheets
- Inspect refractory
- Conduct thickness test on tubes and sheet, if necessary
Powerhouse uses high-powered lights, high-resolution cameras, including snake cameras, and trained eyes to evaluate the internal condition of a boiler.
- Hydrostatically test
The boiler is pressurized with water from a certified hydro test machine. The boiler is tested to 1.5x its design pressure. Certified gauges are also used.
- Replace tubes (Re-Tube)
All tubes must be 100% leak-free and without any visual damage. If not, the tubes are immediately replaced. In almost every case, Powerhouse will replace all boilers tubes, rather than just 1 or 2.
- Repair tube sheet and or shell, if necessary
If this rare instance occurs, Powerhouse is fully certified by the National Board under our “R” stamp and by the ASME under our “S” stamp to make any repairs to the pressure vessel. Our welders have all met the latest requirements of these organizations.
- Replace and or patch all refractory
Every boiler has some type of refractory. Powerhouse uses certified masons to assess and make all repairs necessary to the boiler. We use factory-certified fiberglass forms when pouring new doors.
- Replace all gaskets and seal boiler
Once any type of boiler door is opened, the gasket should never be used again. Powerhouse replaces ALL boiler gaskets during a reconditioning with genuine, factory-certified parts.
- Verify and test all parts and trim
Mechanical tests are performed on all exterior boiler components to ensure the proper working order.
- Test electrical components
Every reconditioned boiler comes with a Powerhouse wiring schematic. We take the time to test every component and connection, ensuring their workability.
- Remove and test the blower motor
We check the blower motor, which can be the most expensive trim item, extensively to ensure its operation. If the blower motor does not pass our tests, it is replaced or reconditioned by a certified facility.
- Replace Pressure Controls
Every reconditioned boiler comes with brand new pressure controls. We never risk reusing any of these controls because of their importance to the proper operation of the boiler.
- Check Programmer
Every controlled operation of the boiler programmer and flame safeguard system is checked.
This unit must perform flawlessly or it is replaced.
- Replace and/or certify safety valves
Every reconditioned boiler comes with properly certified safety valves. If the safety valves meet minimum usage requirements, they are tested and certified by a certified VR facility. If they do not meet our requirements, they are replaced with new valves.
- Test Fire
Powerhouse has full test-fire capabilities and reconditioned boilers are fired and exhaust steam. We have enough fuel, water, and electric to fire up to a 100,000 PPH boiler.
- Clean boiler
- Wire-wheel all paintable surfaces
- Paint boiler
Powerhouse uses automotive quality, heat-resistant paint to prevent chipping and cracking.
- Shrink Wrap
No reconditioned units ship without first being shrink-wrapped to prevent weather damage. Most firetube boilers are 100% shrink wrapped and water tubes are wrapped at the burner end.