Electric steam boilers are a clean, safe and efficient solution for many industrial processes. However, even the most reliable equipment can fail if not properly operated and maintained.
In this article, we review the five most common electric steam boiler problems we see on a day-to-day basis with our customers and how to avoid them easily and cost-effectively.
1. Damage to the resistors due to inadequate water use or lack of purging.
One of the most common failures is the breakage or overheating of electrical heating elements. This is usually due to poor water quality (high hardness or salt content) or lack of regular flushing, which causes scale build-up and incrustations.
How to avoid it
- Use treated or demineralized water to feed the boiler.
- Install a reverse osmosis or decalcification system if necessary.
- Schedule automatic or manual purges at the appropriate frequency, depending on usage.
- Visually check the resistors at each scheduled maintenance.
2. Failures in the inlet or purge solenoid valves
Solenoid valves are key elements in water inlet and blowdown control. They often fail due to debris accumulation, internal wear or lack of cleaning, which directly affects boiler performance and safety.
How to avoid it
- Performs periodic opening and closing tests of solenoid valves.
- Clean or replace filters in the water line.
- Replace solenoid valves that show signs of clogging or irregular response.
- Be sure to use original and quality spare parts.
3. Problems with water levels
Level sensors or probes monitor the amount of water in the boiler. If they become dirty, out of calibration or fail, they can cause constant alarms or even unsafe operation of the equipment.
How to avoid it
- Clean the probes or floatsregularly, especially if the water has impurities.
- Verify that the level remains stable during operation.
- Change the level sensors according to the maintenance schedule or at the slightest sign of failure.
- Uses redundant control devices in critical applications.
4. Electrical and control failures due to poor maintenance
Although electric boilers have fewer moving parts than a gas boiler, the electrical elements(wiring, contactors, PLCs or temperature/pressure sensors) can deteriorate over time.
How to avoid it
- Performs annual electrical inspections.
- Check the condition of connections, insulation and relays.
- Prevents the electrical panel from accumulating moisture or dirt.
- Keep the control software up to date if the system allows it.
5. Absence of planned preventive maintenance
Many users believe that electric boilers are “maintenance free”. This misconception often leads to accumulated breakdowns, unexpected downtime and high repair costs.
How to avoid it
- Implement a preventive maintenance plan, on a monthly, quarterly or semi-annual basis depending on usage.
- Records all tasks performed (purging, cleaning, replacement, checks).
- Train in-house maintenance personnel or contract a specialized technical service.
- Schedule regular inspections to detect problems before they become breakdowns.
Conclusion
A well-maintained electric steam boiler can last for many years with optimum performance. Common problems are easy to avoid with adequate water, frequent blowdowns and good maintenance.
In Giconmes, in addition to manufacturing high quality boilers, we offer original spare parts and technical advice so that your installation always works at 100%.
Do you have doubts about the maintenance of your boiler? Do you need resistors, solenoid valves or sensors? Contact us and we will help you without obligation.