What process is commonly used to repair cracked boiler tubes?

Welding is a highly effective method used to repair cracked boiler tubes as it achieves a strong, durable bond that can withstand the high pressures and temperatures typically found in a boiler. This method restores the integrity of the tube, ensuring that it can continue to function safely and efficiently.

In cases of severe cracks, sleeve repairs may also be employed. This involves adding a sleeve that covers the cracked area, effectively reinforcing the tube and providing an additional layer of protection. This combination of welding and possible sleeve repair is standard practice in the industry, highlighting the importance of structural integrity in boiler operations.

Other methods such as replacing the entire boiler is an extreme and often unnecessary solution for a cracked tube, given the potentially effective repair options available. Patching with duct tape or using caulk may seem like quick fixes; however, they are not reliable methods for handling the high-stress environment of boiler tubes, as they would likely fail under operational conditions.