Commercial Oil Boiler Repair at a Care Home

PHS Engineers Ltd was recently called to a care home where their commercial oil boiler had failed to fire up, causing concern for the facility’s heating and hot water supply. The client reported that, after attempting to ignite, a puff of black smoke had emerged from the flue. Our expert engineer arrived promptly to investigate and resolve the issue.

Initial Diagnosis and Findings

Upon inspection, it became clear that the boiler had become heavily sooted, preventing it from functioning correctly. This soot build-up was likely the cause of the black smoke the client had observed. The engineer quickly removed the soot from the boiler and replaced the faulty nozzle to restore basic functionality.

Further investigation revealed additional issues with the flue and other key components of the boiler system:

• Flue Joint Problem: The joint at the boiler’s flue was not properly sealed, as the foam gasket had shrunk over time. This improper seal could have allowed combustion gases to escape. The engineer removed the flue and sealed the two problematic areas with high-temperature sealant as a temporary fix, recommending that a new gasket be ordered for a more permanent solution.
• Flue Taping: As a precaution, the horizontal part of the flue was taped up to prevent any potential leaks until a permanent repair could be made.

Baffles and Combustion Door Issues

Due to the extensive soot build-up, the boiler’s top two baffles had been subjected to unusually high temperatures, causing them to warp. As an interim solution, the engineer repositioned these baffles to the bottom of the boiler but advised that they be replaced.

Additionally, the boiler’s combustion door was not sealing properly in the bottom left corner. To address this, the entire door board was packed with high-temperature ceramic paper, although the engineer recommended that a new door board be fitted for long-term reliability.

Condensate Trap and Flexi Pipe Replacement

The condensate trap was also blocked, a common issue for boilers operating 24/7 in high-demand environments such as care homes. This blockage was likely affecting the boiler’s ability to condense properly, which could lead to further operational problems. The trap was unblocked, but during this process, the flexible pipe attached to the condensate trap was found to be split. The engineer replaced the pipe and left the old one inside the boiler casing.

Final Outcome and Recommendations

Following the cleaning, repairs, and part replacements, the boiler was fully operational again. By ensuring that the burner no longer pulled in combustion products from the flue or door, the system could run more efficiently and safely. The engineer recommended that, given the care home’s heavy reliance on the boiler, 2-3 services per year would help prevent similar issues in the future.

Commercial Oil Boiler Repair at a Care Home – Conclusion

PHS’s timely intervention ensured that the care home’s heating system was quickly brought back to full working order. By addressing not only the immediate soot issue but also identifying underlying problems with the flue, baffles, and combustion door, our engineer provided a thorough, long-lasting solution. This case underscores the importance of regular maintenance, especially for boilers in high-demand environments, to prevent breakdowns and maintain efficiency.

For all commercial boiler repair and maintenance needs, trust PHS Engineers Ltd for reliable and professional service.