Backup steam boiler

For many industrial plants, steam is a critical utility. A failure, maintenance stop or unexpected outage of the steam boiler leads to production losses, quality problems or a production standstill.

With a backup steam boiler, you have an extra safeguard for your steam supply. When the main installation is temporarily unavailable, the reserve boiler takes over steam production in full or in part, keeping your production process running and reducing the risk of downtimes to a minimum.

The Callens Group specialists help you determine the most suitable backup strategy for your site.

Discuss your options

When is a backup steam boiler worthwhile?

An interruption in steam supply can have major consequences for some production processes. When a continuous steam supply is crucial, a backup steam boiler is indispensable as it takes over steam production during scheduled maintenance, technical failures, peak loads or future capacity expansions. It can take over your entire steam demand or part of it.

5 reasons to choose a backup steam boiler:

  • You want to safeguard the continuity of your steam production.
  • You want to avoid the extra cost of an interruption in steam production.
  • You want to be able to absorb peak loads.
  • You’re anticipating future capacity expansions.
  • You’re looking for extra operational reliability.
Callens stoom back up
Outputup to 100 MW
Capacity25 kg/h to 150 t/h steam
Design pressure0.5 to 100 bar
Efficiencyup to 99 %

Technical specifications of a backup steam boiler

The sizing of a backup steam boiler will depend on the risk a company wants to cover. Some installations are designed to take over the entire steam production if the main installation fails, while others only keep the critical processes running.

That’s why we consider not only the steam capacity, but also factors such as:

  • operating hours
  • critical consumers
  • switchover times
  • available space
  • integration with the existing steam installation

Our specialists analyze these parameters and design a solution that suits the continuity requirements of your production environment to perfection.

advantages

Advantages of a backup steam boiler

The sizing of a backup steam boiler will depend on the risk a company wants to cover. Some installations are designed to take over the entire steam production if the main installation fails, while others only keep the critical processes running.

Maximum operational continuity

Steam supply remains available during unexpected failures or other interruptions.

Less production loss

The risk of downtimes and the associated costs is greatly reduced.

Maintenance without downtime

Scheduled maintenance can take place without affecting production.

Extra capacity at peak load

The reserve boiler can temporarily supply additional steam output when needed.

Protection of critical processes

Sensitive production processes keep running, even in the event of technical problems.

Ready for expansion

The backup installation can support additional production capacity when heat demand rises.

How do you integrate a backup steam boiler into your existing steam plant?

A backup steam boiler is rarely built as a completely separate installation. In most cases, it is integrated within the existing steam plant and connected to the existing steam, feedwater, condensate and fuel network.

The method will depend on the available space, the desired backup capacity and the existing infrastructure. Some companies opt for a reserve boiler that can take over their entire steam production if the main installation fails. Others simply want enough capacity to keep critical processes running during maintenance or failures.

Explore the possibilities
Callens stoom back up 2
Callens brandertechnieker

Maintenance of your backup steam boiler and 24/7 service

The Callens Group’s maintenance and service team makes sure your installation keeps performing at its best, even after commissioning. With an in-house team of more than 120 service and maintenance technicians, we schedule preventive maintenance in line with the legal and technical requirements of your installation.

You can also count on fast support whenever an unexpected breakdown occurs. Thanks to our 24/7 on-call service, an extensive range of spare parts and the expertise of our service technicians, we carry out interventions quickly and effectively.

Even the best maintained installation can malfunction or shut down unexpectedly. That’s why the Callens Group offers various service packages, tailored to the response time and support you need. So even in unforeseen situations, you can count on our expertise.

More information about our service contracts
“Maximizing energy efficiency doesn’t start with choosing a technology, but with mapping out your environment and goals.”

Projects with backup steam boilers

Callens stoom vlampijp Colac 1
Steam boilers Gas-fired Backup +1

Heat from fire-tube boiler to industrial cooking pots

Capacity2 x 3 200 kg/h
Operating pressure13 barg
20230426 153901
Thermal technology Steam boilers Gas-fired +2

From expensive overcapacity to balance with backup steam

Capacity2 x 5T
Seal pressure10 barg
Operating pressure6 barg
Scandinavian Tobacco 2x Viessmann 2 T 13b 1
Thermal technology Steam boilers Gas-fired +1

Steam peaks supported by two fire-tube boilers

Capacity2 x 2 T/h
Design pressure13 barg

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FAQ

Questions? We have the answers.

For many industrial plants, steam is a critical utility. A failure or maintenance stop of the main installation can lead to production losses, quality problems or even a complete production standstill. A backup steam boiler limits that risk and guarantees the continuity of your steam supply.

Not necessarily. Some companies choose to be able to take over the full steam capacity, while others merely want to keep the most critical processes running. The required capacity will depend on your production process, the risk analysis and the desired operational reliability.

Yes. During expansions or upgrades of a steam plant, an existing boiler is often retained as a reserve installation. This maximizes the value of an earlier investment and creates additional redundancy within the steam supply.

That depends on the type of boiler, its output and the chosen configuration. Modern installations can often be operational within a relatively short time, so the impact of a failure or maintenance stop remains limited.

Yes. Many companies use their reserve boiler not only as an emergency supply, but also to absorb temporary peaks in steam demand. This allows the total available steam capacity to be increased flexibly when needed.

Depending on the configuration, the backup installation can be switched on automatically or semi-automatically. This keeps the steam supply available and reduces the impact on the production process to a minimum. Want to know what redundancy is possible within your steam plant? The Callens Group experts will be happy to advise you.

As an EPCS integrator, Callens Group takes charge of the entire process: from on-site analysis and engineering to installation and service. This gives you a single point of contact throughout the full service life of your backup steam boiler. You can find out more about the various steps in our workflow here.

A reserve installation must be tested and maintained regularly to ensure it is operational when needed. The frequency will depend on operating conditions, but periodic test starts and inspections are usually part of the maintenance program.

For companies that permanently require high availability, a fixed backup installation will usually be the most reliable choice. For temporary situations such as maintenance work, overhauls or emergency interventions, a mobile steam boiler can offer a solution. Would you like to know more about mobile steam boilers? Discover our full range of rental boilers here.

For a producer of oils and fats, the Callens Group delivered a new steam plant with a gas-fired backup steam boiler and an HRSG installation coupled to a gas turbine. The existing installation was bedeviled with malfunctions, putting the stability of the steam network and process temperatures under pressure. A backup boiler of 23 tons of steam per hour restored the continuity of the production process. The project resulted in more efficient, more reliable steam production, with a capacity of 23 t/h on natural gas, a design pressure of 18 barg and an operating pressure of 15 barg. 
Learn more about this project.