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Icon Boiler Case Study: Chemours

Icon Boiler Case Study: Chemours

Uncategorized

PROJECT SCOPE

The Fayetteville Chemours facility encountered a significant setback when one of its two watertube boilers malfunctioned, necessitating the remaining boiler to operate at an unsustainable capacity. Urgency arose to restore boiler #2 to full functionality before the upcoming winter season. Initial assessments pointed towards improper burner tuning, causing damage to the inner wall tubes, warranting prompt and professional intervention.

ACTION

The intricate nature of the boiler problems at the Fayetteville Chemours facility necessitated specific expertise and know-how to successfully resolve the issues. In seeking professional assistance, the client turned to Icon Boiler, a renowned and experienced provider of boiler services, equipped with the crucial R-Stamp authorization for boiler tube repairs.

Icon Boiler’s experienced team approached the project methodically and began by replacing the initial 64 tubes that were identified as having defects. In addition, they incorporated two new site glasses, which allowed for improved flame monitoring, thereby enhancing the overall safety and efficiency of the boiler. During the subsequent hydro testing following the initial repairs, potential leaks in other tubes were identified, necessitating the replacement of an additional 130 inner wall tubes.

Additionally, the team discovered broken fittings within the mud drum, which required the replacement of the piping for the connecting nozzle of the sparge tube. This comprehensive approach enabled the team to address the three distinct code repair requirements within a single project, saving the client both time and resources.

By leveraging their technical expertise and specialized skill set, Icon Boiler seamlessly integrated the diverse repair requirements and provided the client with a turn-key solution that not only resolved the critical operational challenges but also ensured complete code compliance and safety.

RESULTS

All specified code repairs, including the intricate replacements and repairs conducted by Icon Boiler, underwent rigorous testing protocols and were approved by the authorized inspector. The meticulous workmanship and adherence to industry standards ensured the safe and efficient operation of the boilers at the Chemours facility, validating Icon Boiler’s commitment to delivering high-quality solutions for complex boiler challenges.

By seamlessly integrating technical expertise with industry compliance standards, Icon Boiler effectively resolved the pressing operational issues faced by Chemours, reinforcing their reputation as a trusted partner for industrial clients.

ABOUT US

Icon Boiler is the premier boiler equipment and service solutions provider in the Southeast. At Icon Boiler we sell, service, repair, and maintain boiler equipment for mission-critical customers throughout the Southeastern United States. Our customers know us to stand for responsive, reliable, efficient, and safety focused service and expertise.

ABOUT OUR CUSTOMER

Chemours, a distinguished chemistry company
committed to fostering a better world through
innovative solutions, caters to diverse industries including automotive, paints, laminates, electronics, construction, energy, and telecommunications.

Rental Ready

Rental Ready

Life Sciences, Uncategorized

If you’ve ever faced a situation that involved a loss of steam production, you know how painful that can be. Any habitable spaces are suddenly at the mercy of the weather. More money, customers, and productivity are lost every minute. It’s not a great situation. Fortunately, it’s nothing you have to worry about, because we will help keep you up and running, no matter what. Whether you’re having planned service or maintenance on your existing boiler, or if unforeseen circumstances take your current boiler offline, we’ve got your back.

PLANNED OUTAGES

Boilers need regular service and maintenance, and some of those procedures can’t be done with the boiler running. Repairs also often require a shutdown. But with the proper planning, you won’t have to endure any interruption of service. If you know you’re going to have to take your boiler offline, contact Icon Boiler’s rental department and we’ll make sure you have the right steam capacity ready to go when the time comes, so at the worst, you’ll only lose a little steam production when the switch is made to the rental boiler. We even have a rental contingency plan available to help you prepare for your rental, including a detailed checklist of what you’ll need to do. We also have experienced professionals who will help you select your size and type of rental equipment.

 

EMERGENCY SITUATIONS

Bad things happen. Sometimes the weather hits you with a sucker punch. Sometimes equipment fails. Natural disasters can strike any time. If you end up getting your boiler knocked offline unexpectedly, we are here to help. We have professionals standing by 24/7 to get the right emergency boiler prepped for launch and on its way to you. Depending on where you’re located, we can have an emergency boiler on-site in a matter of hours. For extremely isolated or remote locations, we even have complete, self-contained boilers built into standard Conex shipping containers that easily travel by truck or ship, to anywhere that has standard cargo logistics capabilities.

 

WHO WE SERVE

From the smallest needs to the biggest, we have the rental equipment to provide however much steam it takes to keep you up and running. We provide emergency boilers for a wide range of industrial applications including factories, oil and gas drilling and refining, and automotive manufacturing. We also have rental boilers for a range of commercial needs including warehouses, office buildings, hospitals, schools, and universities. We even supply rental hot water boilers that are ideal for any place that needs clean, hot water including outdoor events, festivals, retirement homes, apartments, hotels, detention faciltiies, and even disaster areas that need hot water for laundry, cooking, and cleaning.

 

WHAT’S INCLUDED

In most cases, WARE’s rental boilers are ready to hook up the moment they arrive. Every mobile boiler room we send out includes everything needed for safe, efficient operation:

  • Main steam stop valves
  • Safety relief valves
  • Exhaust stub stack
  • Bolt and gasket kits
  • Safety and monitoring equipment
  • Self-contained operator work area and monitoring station

A range of additional equipment is also available depending on your specific application, including:

  • Water softeners
  • Feedwater systems
  • Backup feedwater pumps
  • Blowdown separators
  • Oil storage tanks
  • Economizers
  • De-superheaters
  • Selective catalytic convertors
  • Heat exchangers

Furthermore, you can customize your rental boiler with a selection of optional accessories that can further optimize your boiler for the application, including:

  • Gas Pressure Reducing Stations
  • Steam Pressure Reducing Stations
  • Low Pressure Safety Relief Valves
  • Booster Pumps
  • Gas Flowmeters
  • CO Monitors
  • Remote Monitoring Systems

We have the people to go with the equipment, too. We offer pre-installation consultation from seasoned boiler professionals who know what to ask and what to look for. Our technicians will help get the boiler set up, inspected, and fired up, so you can enjoy turnkey operation. 

Authorized Use Provided by our Partners at WARE Inc. 

Icon Boiler Announces Partnership with Sterlco in the Southeast

Icon Boiler Announces Partnership with Sterlco in the Southeast

Education, Uncategorized

Icon Boiler has announced a new partnership with Sterlco. As part of the partnership, Icon Boiler will now offer a wide range of Sterlco’s high-quality steam control products to customers in North Carolina, South Carolina, and Georgia.

“We are extremely pleased to partner with Sterlco to offer our customers even more options when it comes to quality boiler equipment,” says Myron Burnett, General Manager of Icon Boiler. “Sterlco has a long-standing reputation for innovative and reliable products, and we look forward to working with them to meet our customers’ needs.”

Sterlco’s product line includes condensate units, boiler feed units, pumps, temperature control valves, strainers, steam traps, and hand radiator valves. The company’s products are known for their precision engineering, reliability, and ease of installation and maintenance.

The partnership will allow Icon Boiler to further expand its service offerings to customers in the region, while also providing Sterlco with an even wider distribution network in the Southeast. The increased availability of Sterlco’s products through Icon Boiler will ensure that customers receive prompt service, support, and reliable parts.

The Benefits of Boiler Preventative Maintenance

The Benefits of Boiler Preventative Maintenance

Education, Life Sciences, Uncategorized

Why a Preventative Maintenance Schedule is Essential for Your Commercial Boiler

As a commercial boiler service and equipment provider, we understand the importance of keeping your facility’s heating system running efficiently and reliably. That’s why we cannot overemphasize the necessity of a regular preventative maintenance schedule for your commercial boiler.

Regular boiler maintenance reduces the likelihood of major breakdowns, prolongs the life of your equipment, and saves you unnecessary costs. Here are some reasons why a preventative maintenance schedule is essential for your commercial boiler.

1. Boosts Efficiency and Performance

Regularly servicing your commercial boiler ensures that it runs at optimal efficiency and performance. During maintenance, our technicians will check all components, clean parts, lubricate moving parts, and ensure they are functioning correctly. Therefore, the system works without undue stress to all parts, leading to better heating output and heat transfer, and reduced downtime.

2. Saves on Energy Bills

An efficiently running boiler saves on energy bills. A poorly maintained boiler consumes more fuel and energy to operate, which translates to higher utility costs. An annual maintenance schedule can reduce energy wastage by up to 40% and save you money on your heating bills over time.

3. Minimizes Repairs and Downtime

A commercial boiler breakdown unexpectedly halts your heating and operations, which can be detrimental to any business that relies on a productive work environment. Neglecting boiler maintenance increases the chance of repair and emergency service calls, leading to costly equipment repairs and downtime. However, a preventative maintenance schedule can identify problems early and mitigate them promptly before they become a significant issue.

4. Ensures Safety and Compliance

Regular boiler maintenance is crucial for ensuring the safety of your facility, employees, and customers. Faulty boilers can lead to carbon monoxide leaks or other hazardous situations. By scheduling regular inspections, our technicians can identify any potential safety issues and rectify them promptly. Additionally, adhering to maintenance schedules helps you comply with industry regulations and requirements, maintaining a safe and compliant working environment.

 

In conclusion, a regular preventative maintenance schedule is proactive care that saves you time, money, and, most importantly, assures that your commercial boiler operates optimally all year long. Contact us to schedule regular maintenance or have your commercial boiler inspected today. It’s time to keep your facility’s heating system running safely and efficiently.

 

Let your Icon Boiler representative know if your facility or organization needs assistance in establishing, maintaining, or reviewing your Preventative Maintenance Program. 

Icon Boiler Case Study: Prisma Baptist

Icon Boiler Case Study: Prisma Baptist

Uncategorized

ABOUT US

Icon Boiler is the premier boiler equipment and service solutions provider in the Southeast. At Icon Boiler we sell, service, repair, and maintain boiler equipment for mission-critical customers throughout the Southeastern United States. Our customers know us to stand for responsive, reliable, efficient, and safety focused service and expertise.

ABOUT OUR CUSTOMER

Prisma Health is a not-for-profit health company and the largest healthcare system in South Carolina. The goal is to improve the health of all South Carolinians by enhancing clinical quality, the patient experience and access to affordable care, as well as conducting clinical research and training the next generation of medical professionals.

CHALLENGES

Our client was facing recurring costly repairs and maintenance issues with their Durco horizontal end suction boiler feed-water pumps. With eight pumps constituting their feed-water system, maintaining their operations had become a constant challenge. Additionally, the design of these pumps necessitated an expensive laser level alignment to ensure the special coupling fell within the required tolerance range.

ACTION

Drawing on our extensive experience with the client, our team of sales engineers recognized the customer’s pain points. To address the issues, we collaborated with our partner, GPM Pumps, to design and size a set of DP boiler feed-water pumps and variable frequency drives, aimed at replacing the costly and inefficient Durco pumps.

The design of these DP pumps, which were inline, multi-stage, centrifugal, and vertical, offered numerous advantages to the customer. It included a compact footprint, efficient operation, and simplified maintenance procedures. It is important to note that the installation of these pumps could be completed within minutes, eliminating the need for a specialist laser alignment. Furthermore, these DP pumps were designed with similar flange to flange measurements as the leading competitor, Grundfos, often obviating the need for elaborate piping modifications.

With a comprehensive plan of action in place, our Icon Boiler service team flawlessly executed the project. Within a brief one-week period, they successfully repiped the first deaerator, installed the pumps and drives, and commenced the commissioning process. Shortly after bringing the first deaerator online, they swiftly completed the second deaerator installation.

As a result of our team’s efforts, the customer now enjoys the assurance that these pumps efficiently respond to fluctuations in feed-water demand, consistently operate at their optimal duty points, and, in the event of high temperature seal failure in a few years, readily available replacement parts can be obtained within 1-2 weeks. Moreover, the ease with which the pumps can be rebuilt by any of the customer’s operators provides them with an added level of confidence.

RESULTS

By addressing the costly repairs, maintenance issues, and design constraints of the existing Durco pumps, our solution has significantly improved the operational efficiency and reliability of the feed-water system for our client. The team’s successful implementation of the DP pumps and variable frequency drives has freed up valuable space, enhanced energy efficiency, reduced maintenance complexity, and eliminated the need for costly laser alignment. With these improvements, our client can now focus on their core mission of providing exceptional healthcare services while enjoying the peace of mind that comes with a reliable and cost-effective feed-water system.

 

Contact the experts at Icon Boiler to determine if a pump replacement is the right choice for your boiler system.

Prolong the Life of Your Boiler: Icon Boiler’s Comprehensive Mechanical Support and Repair Services

Prolong the Life of Your Boiler: Icon Boiler’s Comprehensive Mechanical Support and Repair Services

Education, Life Sciences, Uncategorized

With our R-Stamp certification, we guarantee our expertise in delivering exceptional boiler repairs that keep your equipment functioning at its best. Our licensing for boiler code repairs ensures safe operation and extends the lifespan of your boiler.

Distinguishing Routine Maintenance from Boiler Code Repair

Regular maintenance involves replacing sacrificial elements that break down over time, protecting the pressure-retaining parts. This helps to maintain efficiency and prevent further damage. Boiler code repairs, on the other hand, focus on identifying and addressing defects in the pressure-retaining components themselves.

At Icon Boiler, we are qualified to handle both routine maintenance and code repairs for your boiler, ensuring comprehensive care.

Expanded Services for Maximum Performance

In addition to repairs and maintenance, Icon Boiler offers a range of expanded services aimed at optimizing your boiler’s performance rather than needing to replace the entire system.

  • Boiler retubing: Replacing worn-out or damaged tubes for restored peak performance.
  • Replacing feed-water inlet couplings: Ensuring a reliable water supply and mitigating code issues.
  • Nozzle repairs: Contributing to efficiency and safe boiler operation.
  • Retacking of baffle shelves: Optimizing heat transfer and maintaining boiler efficiency.

Understanding the Common Causes of Code Defects

Boiler problems can arise due to various reasons, so it is crucial to identify the root cause in order to properly fix and maintain them. Below are some common boiler issues that can lead to code defects: 

  • Poor water chemistry: Can lead to oxygen pitting and compromise the boiler’s integrity and performance.
  • Thermal shock: Occurs when hot metal comes into contact with cool feedwater.
  • Accumulation of scale or soot: Lowers heat transfer efficiency and can result in code defects.

Trust Icon Boiler for Unmatched Boiler Repair and Service

When it comes to boiler repair and service, Icon Boiler stands out as a trusted industry leader. With our expertise in boiler repairs, along with the necessary certifications and licenses, we are committed to providing high-quality and reliable service. By choosing Icon Boiler, you can have confidence that your boiler is in capable hands.

Contact us today to learn more about our services and experience the difference with Icon Boiler. Together, we’ll ensure optimal performance, efficiency, and safety for your boiler.