Watertube Boiler Repair

Denver International Airport had a 75,000 lb/hr watertube boiler with a leak on the water side. They knew it was leaking. They didn't know where.

That's common on a watertube boiler. The tubes sit behind casing, insulation and refractory, so you can't see them from outside. The leak could be in a wall tube, back in the convection section, or at one of the drums. The only way to find it is to open the boiler up and test it.

Finding The Leak

We opened up both drums and the inspection ports, then ran a hydro test and looked for water. We also cut a window in the casing at the back of the boiler so we could see into the convection section. After that we vacuum tested the tubes until we had found every leaking tube and marked it.

Making The Repair

Our Denver Boiler Repair team cut out the leaking tubes, welded in new tube from the boiler manufacturer, and ran another hydro test to make sure it held.

With the tubes done, we rebuilt the side of the boiler we had opened up. The old casing came off. New seals, insulation, pins and clips went on, and we welded new casing over the top. We closed up the window at the back too. The crew worked 10-hour days, seven days a week, until it was finished.

About Us

Rasmussen Mechanical Services is a full-service mechanical contractor with over 55 years of experience supporting commercial and industrial facilities. Our teams work across a wide range of mechanical systems, providing the knowledge and field experience needed to complete projects of varying size and complexity.

Each project we take on is approached with careful planning, clear communication, and a focus on quality execution. Our crews are experienced working in active facilities, coordinating with other trades, and adapting to site-specific conditions to keep work moving efficiently and safely.

From initial coordination through project completion, Rasmussen Mechanical Services remains focused on delivering dependable results that support long-term system performance. This project reflects our ongoing commitment to practical solutions, skilled workmanship, and consistent execution across every job we perform.