Client: Byworth Boilers Ltd
The Brief
Byworth Boilers Ltd contacted our team at DK Welding Services Ltd to replace the shell section on an industrial boiler system. This defective boiler part required urgent attention as it’s the key component of containing water, steam and combustion gases.
The Solution
Our goal was to quickly assess the damage and faults of the shell section, replace it, carry out all necessary tests and ensure the whole system met insurance and compliance standards.
Work Completed
We conducted a comprehensive service for Byworth Boilers Ltd, from removing the faulty component to full replacement, inspections and testing to ensure full operation and safety.
- The defective boiler shell section was removed, with the surrounding area fully prepared and cleaned, followed by interim MPI (Magnetic Particle Inspection) to confirm the parent material was free from defects and suitable for repair.
- Detailed preparation and finishing of the shell surface were carried out to ensure accurate fit-up, alignment and to prevent distortion during welding.
- The replacement shell D-patch section was aligned, fitted and tack-welded into position, ready for insurance surveyor inspection prior to full welding.
- In-house MPI was conducted on the tack welds to verify weld integrity before progressing to the next stage of the repair.
- Root and hot pass welding of the tube-plate to shell attachment weld was completed, followed by additional in-house MPI to ensure no cracking or defects were present prior to weld capping.
- Full welding of the shell D-patch repair was completed, with the area prepared for final ultrasonic testing (UT) and MPI.
- Boiler components, including door closure fittings and lagging rings were reinstated, restoring the unit towards full operational condition.
- Final inspection stages were carried out, including post-weld UT and MPI testing, confirming that the defective boiler repair met insurance and industry compliance standards.
The Finished Project
By completing this shell section replacement with full NDT, insurance-approved inspections and precise coded welding techniques, we’ve helped our client return their boiler to safe, efficient and compliant operation. DK Welding Services Ltd provided a full end-to-end repair service – from defect removal and preparation through to final testing.
