Electric steam boilers use either immersion resistance elements or electrode technology to convert electrical energy to heat. While they have no burner or combustion components, they have their own set of wear parts, heating elements degrade over time, electrode surfaces erode, insulators crack, and electrical contactors wear from repeated switching cycles.
AQ Process Systems sources and exports replacement electrical and mechanical components for both resistance-element and high-voltage electrode boilers. We supply from OEM manufacturers and approved equivalent suppliers to ensure correct ratings, dimensions, and certifications.
All electrical components are supplied with appropriate certifications (UL, CE, IEC) and rated for the correct voltage, amperage, and watt density for your specific boiler model.
| Component | Specification | Description |
|---|---|---|
| Heating Elements & Electrodes | ||
| Immersion Heating Elements | Incoloy 800 / SS 316L | Flanged | 3-100 kW per element | Tubular immersion heating elements, flanged mounting, available in standard and custom lengths and ratings. |
| Electrode Assemblies | High-voltage electrodes | Steel or graphite | 6kV-25kV | Electrode rods, mounting brackets, and insulator supports for high-voltage electrode boilers. |
| Electrode Insulators | Porcelain or PTFE | High-voltage rated | Electrical insulation bushings that isolate electrode assemblies from the boiler shell. |
| Electrical Components | ||
| Power Contactors | 3-phase | Various amperage ratings | Main power contactors and auxiliary contacts for element switching, rated for boiler cycling duty. |
| Power Thyristors / SCRs | Phase-angle or burst-fire control | Silicon Controlled Rectifiers for proportional power control in modulating electric boilers. |
| Step Controllers | Multi-step switching | PLC or relay-based | Step controllers that stage heating elements on/off to match steam demand. |
| Fuses & Circuit Breakers | HRC fuses, MCCBs | Rated per element circuit | Over-current protection devices for individual element circuits and main power supply. |
| Level & Pressure Controls | ||
| Water Level Probes | Conductivity type | Multi-point | Electronic level sensing probes, low-water cutoff, feed pump start/stop, and high-water alarm points. |
| Pressure Switches | Adjustable setpoint | SPDT/DPDT | Operating and high-limit pressure switches for boiler pressure control and safety cutoff. |
| Safety Valves | ASME or CE certified | Bronze or SS body | Pressure relief valves sized and certified for the boiler's rated capacity and design pressure. |
| Level Gauge Glasses | Reflex or transparent | Borosilicate | Direct-reading water level gauges for visual level indication. |
| Control Systems | ||
| Control Boards / PLCs | OEM-specific | Programmed and tested | Main logic controllers, PLC modules, and HMI displays, pre-programmed for the specific boiler model. |
| Temperature Sensors | RTDs, thermocouples | Thermowell-mounted | Steam temperature, feedwater temperature, and element sheath temperature monitoring sensors. |
| Current Transformers | Ring-type CTs | For element monitoring | Current transformers for individual element health monitoring, detecting open or shorted elements. |
Parts are matched to OEM material specifications and dimensional tolerances. Please provide the equipment manufacturer, model number, and serial number (if available) for precise part identification. Mill Test Certificates (MTC) supplied with all tube materials per EN 10204 3.1.
The most frequently replaced parts in electric boilers are heating elements (resistance degradation and sheath corrosion), water level probes (scale fouling), power contactors (switching cycle wear), safety valves (periodic recertification), and control boards (component aging). Electrode boilers additionally require periodic electrode and insulator replacement.
Resistance heating element lifespan depends on water quality, operating temperature, and watt density. With good feedwater quality, elements typically last 3-7 years. High watt density, hard water, or high-TDS feedwater shortens element life. Electrode boilers may need electrode re-profiling every 2-5 years.
Resistance boilers use immersion heating elements (similar to large water heater elements) and standard-voltage electrical components. Electrode boilers use high-voltage electrodes immersed directly in the water, requiring specialised high-voltage insulators, electrode assemblies, and water conductivity control systems. The spares are fundamentally different between the two types.
Yes. We supply electrode assemblies, porcelain insulators, water conductivity control valves, and high-voltage electrical components for electrode boilers from PARAT Halvorsen, Precision Boilers, and other manufacturers. All parts rated for the correct system voltage (typically 6kV-25kV).
We supply replacement heating elements compatible with Cleaver-Brooks, Fulton, Vapor Power, Chromalox, Sussman, and other electric boiler manufacturers. Elements are matched by voltage, wattage, flange size, and insertion length. Please provide your boiler model number for exact specification.
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