Industrial boilers are the backbone of many operations, powering production lines, heating systems, and critical processes. But when they fail, the consequences can be devastating, including unplanned downtime, safety risks, and skyrocketing repair costs. This is why understanding boiler problems and solutions is vital for any facility that relies on these heavy-duty systems.
Every plant manager or maintenance team has faced frustrating situations: unexpected shutdowns, uneven heating, or efficiency drops that threaten output. You might wonder: What is the most common problem with industrial boilers? Or when things go wrong, how do you troubleshoot a boiler problem without wasting precious time and resources? These challenges can feel overwhelming, especially when production deadlines and energy costs are at stake.
If these concerns sound familiar, you’re not alone. This guide provides practical insights into boiler problems and solutions that keep operations running smoothly.
Most Common Industrial Boiler Issues and How To Fix Them
Below are some of the most common boiler problems and solutions to help extend the lifespan of your industrial system.
Leaking Fluids
Leaks can happen almost anywhere in the system if you run a steam or hot water boiler. While visible dripping around the pipes or tank may be noticeable, some leaks, such as water spilling through your air vents, may not necessarily be so obvious. Hidden leaks make it far more difficult to pinpoint the issue precisely and demand the use of a water meter.
By determining if water is being lost in a closed system, a water meter can locate concealed leaks. A closed system leak will eventually cause the system to shut down because, over time, the available water level will decrease.
When a system leaks but the water level doesn’t decrease considerably, atmospheric moisture is likely getting into your boiler system. It can accelerate the deterioration of your boiler investment because atmospheric moisture is untreated water.
Solution:
If your system leaks, it might be more practical to replace the other sections of the system at the same time as you remove the leaking portions. This is due to the labor intensiveness needed to remove leaky boiler components from awkward angles. Under no circumstances should you ever try to fix a leak yourself.
Poor Maintenance Processes
Irregular maintenance is typically the cause of every boiler issue, regardless of its physical appearance. Depending on how frequently it is used, every boiler should have routine maintenance done. If you don’t do routine maintenance, you can easily overlook minor concerns that develop into far more serious problems and even possible injuries.
In the worst situation, failing to examine your boiler could result in a catastrophic boiler explosion due to combusting fuel, low water levels, failed trip switches, and more.
Solution:
Regular inspections can identify problems so that they can be addressed before they escalate to more serious issues. Make sure to plan routine maintenance and avoid skipping out on it. You can even perform a number of visual examinations on your own.
Missing Insulation
Your system’s efficiency will suffer if insulation is missing. Your boiler’s insulation helps to keep heat inside the system. If the heat isn’t kept inside the system and can easily dissipate, it will take more fuel to keep the pressure and temperature where they should be.
The insulation that is missing is barely noticeable. The most efficient method for detecting this common boiler issue is with a thermal imager, but most facilities have limited or no access to one.
Solution:
It’s possible to identify a missing insulation issue by seeing rising energy expenses without an increase in boiler usage. If you feel that you have missing insulation, the best solution is to contact an experienced boiler maintenance professional for an inspection.
Blockages
Your boiler system may be considerably affected by poor water quality. Scale deposits made of calcium and other minerals can build up on your boiler and pipes, slowing or stopping the flow of steam. Your system’s deposits will increase the quantity of fuel needed to produce the same result.
Solution:
It is a good idea to have a water treatment system for your boiler. Water treatment equipment works to prevent buildup and other problems caused by water minerals.
Low or No Heat Production
There are a variety of potential commercial boiler issues that might result in low or no heat production, ranging in severity from minor to major. Less serious problems include unclean burners that prevent enough heat from passing through could be the cause of poor or no heat generation. Burners can become clogged with dust and debris, which can be a major fire hazard.
Other possible causes may include a broken pump, a broken thermostat, a faulty ignition, or a safety switch that is causing automatic turnoff.
Solution:
It’s important to regularly inspect and clean the burners in your boiler for both your safety and convenience. No matter what kind of commercial boiler issue you’re having, you can’t be sure what’s to blame until you hire an expert to look at it.
Automatic Boiler Shutoff
There are a number of reasons why your boiler system can abruptly shut off. The thermostat may not be operating properly and provide false temperature readings, or it may be completely faulty and provide no data at all. Another explanation can be a severe drop in air pressure, a broken pump, or obstructions in the valve.
Solution:
If your boiler system shuts off on its own or simply won’t turn on in the first place, then you should schedule a service appointment with an experienced expert to identify and fix the problem.
Pilot Light Keeps Going Out
When the pilot light keeps going out, it often points to issues with airflow or components inside older gas boilers. Draughts blowing through the boiler can interrupt the flame, and dust or debris buildup on the gas nozzle can block the gas supply.
Another frequent culprit is a faulty thermocouple, a small but essential safety device that shuts off the gas supply if it detects the flame has gone out. If the thermocouple becomes worn, corroded, or loose, it may wrongly signal that the pilot light has failed, cutting the gas supply to the boiler.
Because the pilot light is linked to other gas appliances and the central heating system, this problem can quickly escalate into a full boiler breakdown if left unresolved.
Solution:
Start by cleaning the pilot light assembly and removing any dirt or debris from the nozzle. If the flame still doesn’t hold, check whether the thermocouple is working correctly. In many cases, a replacement thermocouple can solve the issue.
Inspect the surrounding gas supply lines to confirm there are no obstructions or leaks. For safety, professional boiler repair is recommended, as faulty gas appliances can pose serious risks.
Low Boiler Pressure / Pressure Drops
Low boiler pressure is a common cause of heating system inefficiency and often shows up on the boiler’s pressure gauge. If the reading is below the recommended level, the hot water supply may run weak or cut out entirely.
Pressure loss is usually linked to system leaks, bleeding radiators (which release air trapped inside the pipes), or a defective pressure relief valve. In modern systems, the problem can also stem from internal components such as the pump seal or filling loop.
Water loss from the closed heating circuit is another potential cause, particularly if the boiler’s built-in pressure gauge keeps dropping despite topping up. Persistent low pressure can lead to bigger issues like boiler failure if ignored.
Solution:
Re-pressurise the system following the instructions in your boiler’s manual, usually by opening the filling loop to restore the system’s pressure. Monitor the boiler’s pressure gauge afterward to ensure the reading stabilises within the safe zone.
If low pressure continues, check for visible leaks, particularly around the pressure valve, pipework, or radiators. Inspect the pressure relief valve to confirm that it’s sealed properly. If the issue lies deeper, such as with hidden leaks or faulty components, call a qualified engineer for further boiler troubleshooting.
Kettling Noises (Boiler Sounds Like a Boiling Kettle)
A boiler that makes a kettling noise, similar to water boiling in a kettle, indicates restricted water flow in the heating system. This usually happens when scale or sludge builds up on the heat exchanger, preventing hot water from moving efficiently through the pipes.
The trapped water overheats, creating steam bubbles and a loud whistling or rumbling noise. This is especially common in hard water areas, where mineral deposits form quickly inside gas boilers. If ignored, kettling increases strain on the boiler, reduces efficiency, and may trigger overheating shutdowns or eventual boiler failure.
Solution:
To clear the restriction, engineers often carry out a power flush, pushing water and cleaning chemicals through the heating system to remove sludge and limescale. In some cases, descaling treatments are applied directly to the heat exchanger to restore proper water flow.
Regular maintenance helps prevent severe build-up, particularly in areas with hard water. Fitting a scale reducer or magnetic filter can also minimise future blockages and prolong the life of the boiler.
Boiler Not Responding to Thermostat
When a boiler fails to respond to thermostat settings, the heating system struggles to maintain the desired temperature. The issue may come from incorrect thermostat settings, weak batteries in wireless thermostats, or loose wiring connections between the thermostat and boiler.
In some situations, a faulty thermostat sensor may fail to detect the room temperature accurately, causing the boiler to remain idle. Because modern systems rely heavily on precise controls, even minor faults can disrupt the hot water supply and home heating.
Solution:
Verify the thermostat settings to confirm that the temperature is set accurately. If the model requires batteries, change them and look at the wiring for breaks or loose connections. Additionally, resetting the thermostat might assist in reestablishing communication with the boiler.
If the thermostat itself is defective, replacing it with a compatible unit will solve the issue. A professional boiler repair technician can test whether the fault lies in the thermostat or within the boiler’s internal controls.
Leakage of Valves and Fittings
A leaking boiler often originates from worn or corroded valves, seals, or fittings. Over time, components such as the safety valve, pressure relief valve, check valve, or drain valve can weaken due to constant pressure and temperature changes. Improper installation or excessive boiler pressure can also cause leaks. Even small leaks reduce water pressure and can damage nearby gas appliances or flooring if not addressed promptly.
Solution:
Carry out regular inspection of all valves and fittings, especially the safety valve and pressure relief valve, which protect the boiler from overpressure. Replace any components showing corrosion, cracks, or signs of wear.
Keeping the system’s pressure within the recommended range will help prevent leaks from developing. For a persistent leaking boiler, professional boiler troubleshooting is essential to identify hidden faults and restore safe operation.
Water Shortage / Low Water Level
Running a gas boiler without sufficient water is extremely dangerous, as it risks overheating and damaging the system. Low water levels can result from a failure in the feedwater supply, blocked or frozen condensate pipes, or a malfunctioning automatic filling system.
Sometimes, the water meter or gauge glass may fail to give accurate readings, leading to unnoticed shortages. Operating with low water pressure or a shortage of supply puts the boiler at high risk of breakdown or structural damage.
Solution:
Regularly monitor the boiler’s pressure gauge or built-in pressure gauge to ensure water levels remain within the safe range. Keep the feedwater supply reliable, and maintain or replace gauges that no longer display correct readings.
Frozen condensate pipes should be thawed and insulated to prevent recurring blockages. Safety interlocks on modern systems should be checked to ensure they shut down the boiler when water levels drop dangerously low.
Boiler Explosions and Safety Failures
Though rare, boiler explosions and severe safety failures are usually the result of multiple neglected issues such as overpressure, corrosion, structural fatigue, or defective safety valves.
When a boiler’s construction is weakened by cracks or metal fatigue, high pressure or overheating can push it past its safe operating limits. A frozen condensate pipe, faulty thermocouple, or persistent low pressure might seem minor on their own, but together, they increase the risk of a major boiler failure if left unresolved.
Solution:
Ensure regular inspection of the boiler’s structural components, paying attention to signs of corrosion, cracks, or weakened materials. Safety appliances such as the pressure relief valve must be tested and replaced if faulty.
Strict adherence to boiler troubleshooting, routine servicing, and industry safety protocols helps prevent catastrophic incidents. When in doubt, always consult a professional heating engineer for boiler repair to guarantee safe operation of all gas appliances.
How To Prevent Commercial Boiler Issues
Your commercial boiler system is essential to the year-round warmth and comfort of your company, your staff, and your customers. As a result, it’s critical that you take every precaution to ensure that your boiler system is always efficient and running properly. Additionally, maintaining your boiler system will result in long-term financial savings. Here are a few techniques to shield your company against troubles with commercial boilers.
- Create checklists to ensure that things are routinely inspected
- Perform regular visual checks in the areas surrounding the boiler
- Perform annual checkups to ensure everything is in proper working condition
- Schedule routine maintenance and service appointments
- Make sure that pipes are properly insulated
- Check for leaks daily
- Turn it on daily
The preventative maintenance procedures you follow directly affect your ability to keep your equipment operating effectively, safely, and dependably. Meanwhile, doing routine boiler inspections will lengthen the lifespan of your equipment, lower operating expenses, and reduce downtime.
Naturally, as the years pass, some components will need to be repaired or replaced, and your system will need to be thoroughly cleaned on a regular basis to avoid fire threats. Still, the expense of maintenance and repairs is minimal when compared to the cost of getting a whole new boiler.
Importance of Industrial Boiler Maintenance
One of the most valuable and important assets at the majority of plants and refineries is industrial boilers. They are essential to the creation of energy and other industrial operations. Because they represent such a significant investment, boilers are very valuable assets that require regular maintenance and inspection. Good industrial boiler maintenance is important for a number of reasons.
Regular Scheduled Maintenance Helps Prevent Emergency Shutdowns
One of the most significant reasons why good boiler maintenance is so important is that it helps prevent boiler-related emergency shutdowns. In most industrial facilities, boilers are essential pieces of equipment. The plant’s entire operation could halt if the boiler breaks, halting production and costing the facility lost productivity.
Boiler Maintenance Increases the Boiler Efficiency
Boilers consume a lot of fuel. The boiler must run as effectively as possible in order to maintain low fuel and energy expenditures while optimizing output. The ability to identify and address boiler efficiency issues depends heavily on routine maintenance and inspections.
Scheduled Boiler Maintenance Increases the Lifespan of the Boiler
Boilers are very expensive capital purchases. No industrial plant or refinery will want to purchase a new boiler because they did not take sufficient care of their old boiler. Maintaining boilers properly helps them last longer and reduces the need for expensive replacements.
Routine Boiler Maintenance Helps Reduce Accidents
At almost all industrial plants and refineries, safety is of utmost importance. Accidents not only have the tragic risk of injuring human staff, but they also have the potential to severely damage the facility’s structure. By properly identifying and addressing possible issues before they might cause accidents, good industrial boiler maintenance helps prevent boiler-related mishaps from happening.
Boiler Maintenance Saves Money
A common thread among all of these significant advantages of proper boiler maintenance is that it ultimately saves the business money, whether the financial savings come from avoiding shutdowns, boosting productivity and efficiency, keeping the boilers in operation for longer, or preventing accidents. Regular boiler maintenance, inspections, and minor repairs require only a tiny relative outlay of cash but ultimately yield a significantly higher return.
Boiler Maintenance Improves Compliance, Regulations, and Audits
For an organization to be in compliance with rules and regulations, proper boiler maintenance is crucial. There are rules in effect in the majority of states and some municipalities that mandate annual boiler inspections by licensed inspectors.
Businesses should generally follow appropriate boiler maintenance procedures in order to comply with general emission and safety standards. Regular boiler maintenance should be a routine aspect of day-to-day operations as well as a key component of more major plant turnarounds.
Take Charge of Industrial Boiler Maintenance with eWorkOrders CMMS
One of the most important pieces of machinery utilized in industrial processes is the boiler. Boiler failure can result in financial losses and disruptions to operations. In the worst-case scenario, it will do catastrophic damage, claiming lives and destroying property.
Comprehensive maintenance schedules, checklists, and other preventative strategies must be put in place to manage your boilers more efficiently. One way to help keep up with preventative maintenance is to use CMMS Software (Computerized Maintenance Management Software). This allows you to schedule preventative maintenance in advance so that it is never forgotten by accident.
With this software, you can make sure the boiler is checked on a regular basis and that any upkeep is always done consistently and not pushed aside when other work is needed. CMMS helps in a number of ways as well, such as keeping up with your assets, scheduling work orders, and, of course, preventative maintenance measures. It also plays a major role in workplace safety by minimizing risks and ensuring compliance. In fact, there are many proven benefits, such as the 6 ways CMMS improves safety across different industries.
If you would like to learn more about how eWorkOrders can help you maintain industrial boilers or any other types of equipment or company assets, contact us for a free demo today.
Conclusion
Industrial boilers are critical assets, and neglecting them can lead to costly downtime, safety hazards, and shortened lifespan. However, by understanding common boiler problems and solutions, facilities can take proactive steps to keep systems reliable and efficient. From leaks and blockages to low pressure and poor maintenance, each issue has proven fixes that protect operations and extend equipment life. Moreover, with routine inspections and preventive care, many risks can be avoided entirely. To simplify this process, eWorkOrders CMMS helps streamline maintenance, schedule inspections, and ensure compliance. Take charge of your boiler maintenance today. Contact eWorkOrders for a free demo and safeguard your operations.
Frequently Asked Questions
What are the common boiler troubles?
Common boiler troubles include leaking pipes, low pressure, thermostat malfunctions, strange noises like banging or whistling, ignition failure, and uneven heating. Scale buildup, poor maintenance, and air trapped in the system also frequently contribute to recurring boiler issues.
How to troubleshoot boiler problems?
To troubleshoot boiler problems, check water pressure, reset the thermostat, bleed radiators to release trapped air, and inspect pilot lights or ignition systems. If issues persist, call a qualified technician for deeper diagnostics, cleaning, repairs, or part replacements.
What is the average lifespan of an industrial boiler?
An industrial boiler typically lasts 20 to 30 years with proper maintenance. Lifespan depends on usage, fuel type, water quality, and routine inspections. Regular servicing, descaling, and replacement of worn parts are essential for maximizing operational efficiency and durability.
