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Facing Similar Technical Challenges?
Discuss your facility's EPC and technical engineering needs with our team of experts. We guarantee precise, safe, and efficient execution to global standards.
A steam boiler is the main heart of a processing industry production facility. The stability of the hot steam supply largely determines the smooth running of the entire manufacturing process every day. Therefore, the 5-ton boiler repair project is a highly crucial mechanical maintenance agenda. PT Tri Daya Maxima successfully completed this crucial steam engine maintenance project. This strategic project was commissioned by PT Universal Agri Bisnisindo.
The completion of this steam boiler capacity upgrade project is tangible proof of our technical expertise. We not only repaired damaged components but also upgraded the automation system. The 5 Ton per Hour (Tph) steam capacity can now operate at its highest efficiency point. This achievement further solidifies our position as a trusted mechanical engineering contractor.
Background of the 5-Ton Boiler Repair Project in Bekasi
This agribusiness processing facility is located in a highly strategic industrial area. This engineering project was executed at the plant facility located at Jl. Raya Narogong Km 13.5. This operational area is situated in the Bantar Gebang district, Bekasi City, Indonesia. The dynamic plant location required us to implement extremely strict logistics management.
The execution time for this 5-ton boiler repair project was regulated with high precision. The delivery period for fabricated components was targeted at a maximum of 4 weeks. This duration is calculated right after the official Purchase Order (PO) was issued by the client. After the goods arrived at the Handover Location, the installation process had to be completed within 2 weeks.
The material delivery system utilized Franco delivery directly to the project site. This means that all transportation costs and delivery risks are entirely the responsibility of our team. Please study our mechanical project completion track record on the Our Construction Services Portfolio page.
Warranty Standards and Reliability of the 5-Ton Boiler Repair
Carrying out repairs on high-pressure vessels carries an extremely high-risk profile. Occupational Health and Safety (OHS) is always the top priority for our technicians. We implement pipe welding and jointing guidelines that refer to global standards. You can read the pressure vessel standard guidelines on the official website of the American Society of Mechanical Engineers (ASME).
Our team’s quality commitment is proven through the issuance of a dual warranty guarantee. We provide a full 12-month material warranty from the time the components arrive on-site. Furthermore, we also provide a 3-month warranty for the installation workmanship. This installation warranty period begins after all work is declared complete and operating normally.
Integrated Boiler Maintenance Scope of Work
This industrial steam boiler performance upgrade project is a concrete manifestation of integrated mechanical services. The scope of work is divided into several mutually supporting completion stages. Here is a detailed breakdown of the fabrication and repair stages that have been completed to 100%:
1. Fabrication of Steam Header and Feed Water Tank
The initial construction stage was the manufacturing of the main components for pressurized hot steam distribution. We executed the heavy-duty Steam Header fabrication stage for the 5 Tph capacity Boiler’s needs. This Steam Header functions vitally to distribute steam flow to various production process areas.
In addition, we also designed and fabricated a precision Feed Water Tank unit. This feed water supply tank was designed using stainless steel plate material. We also procured a 100 Kg capacity Regenerant Tank made of Polyethylene material. This equipment is essential to keep the boiler feed water treatment circulation optimal.
2. Repair and Installation of Steam Piping Lines
This phase is a crucial part of restoring the plant’s steam boiler piping circulation. We carried out repairs as well as the installation of new water and steam pipelines. This work included crucial repair stages in the Feed Water Line area. We also supplied and installed the inlet feed water pump with high accuracy.
Our team also handled component leak points that hindered the machine’s operational performance. We successfully repaired the sight glass, which had previously suffered severe leakage. The replacement of gasket components on the Safety Valve flange connections was also carried out meticulously.
3. Boiler Burner Upgrade and Repair
Fuel combustion performance heavily determines the heating temperature efficiency inside the steam boiler. We carried out thorough repair, servicing, and optimization work on the Boiler Burner unit. We ensured the combustion flame was stable again and its fuel consumption was more economical.
The greatest achievement in this stage was the renewal of the machine’s mechanical combustion operating system. We upgraded the engine system from manual control to an automatic system. To ensure accuracy, we completed the calibration of the pressure gauge on the pump. This new system makes the steam engine much smarter, safer, and easier to operate.
4. Repair of Exhaust Ducting and Chimney
High-temperature residual combustion exhaust gases must be channeled safely into the air. The scope of this 5-ton boiler repair project also included exhaust gas line maintenance. We completed repairs on the plant’s Exhaust Ducting and Chimney facilities.
This work involved patching thinned chimney steel plates due to hot corrosion processes. We also reinforced the chimney support frame structure to withstand strong winds. The plant’s exhaust gas flow can now be channeled perfectly without any risk of toxic gas leakage.
Conclusion on the Reliability of PT Universal Agri Bisnisindo's Boiler Facility
The completion of all mechanical projects at the Bantar Gebang plant facility is an outstanding achievement. Fabrication execution was completed in 4 weeks, followed by precision installation over 2 weeks. The synergy between mechanical fabrication expertise, automation electrical systems, and piping utilities operated optimally.
The plant’s steam boiler machine facility now operates much more efficiently, economically, and stably. The reliable readiness of this machine is fully guaranteed through a one-year material warranty and a three-month installation warranty.
Does your industrial company also require steam boiler system repair and upgrade services? Please contact our internal expert team immediately to conduct a technical inspection. We are always ready to design and realize reliable machine efficiency improvement solutions for your plant.
