Fewer unexpected outages: Scheduled inspections, condition monitoring, and proactive part replacement keep your boiler running — reducing unplanned downtime by up to 40%.
End-to-End Boiler Service, Maintenance & Support
Maximise uptime, reduce breakdowns and improve system efficiency with our tailored service programs.
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Specialist support beyond boiler maintenance — from spare parts to combustion engineering and energy consulting.
Maintenance Programs
Tailored service agreements — scheduled yearly or monthly around your operation — keep your boiler compliant with Australian Standards and running at peak efficiency. From planned annual shutdowns to steam-trap audits and panel upgrades, we help you avoid unplanned downtime and extend equipment life.
Breakdown & Repairs
24/7 emergency response from O’Brien technicians, backed by an extensive national spare-parts inventory, gets your plant back online fast. We diagnose the root cause — not just the symptom — and carry out repairs with minimal disruption to production.
Installation & Commissioning
Full lifecycle delivery of new and replacement boiler systems — from engineering and procurement to on-site installation and commissioning. Every system is sized to your process and signed off to Australian Standards, so it runs safely and efficiently from day one.
Inspections & Compliance
Independent inspections and statutory compliance, including pressure-vessel registration, design verification and gas and appliance submissions to the relevant authorities. We keep your documentation current and your plant safe, reducing regulatory risk across every site.
Boiler breakdown & emergency repairs
When an industrial boiler breaks down, isolate the unit safely, record the alarm or lockout code, protect production with a fallback, then call a qualified boiler technician. Those four steps, in that order, decide whether an outage costs you an hour or a shift.
- 01
Isolate
Shut the unit down to the manufacturer's procedure and lock out fuel and power. Do not reset a lockout before the cause is known — a repeated reset on a low-water or flame-failure fault can turn a repair into a replacement.
- 02
Record
Photograph the control panel. Note the alarm or lockout code, the water level and the pressure at the moment of failure. A technician diagnoses far faster from that record than from a description after the fact.
- 03
Protect production
Switch to a standby unit, shed non-critical steam load, or arrange a temporary hire boiler if the outage will run long. Decide this in the first hour, not the third.
- 04
Call a technician
O'Brien runs a 24/7, 365-day nationwide breakdown response with parts on hand and in-house custom gasket manufacturing, so common failures do not wait on a supplier.
Most industrial boiler breakdowns trace back to five causes: low water, flame failure, scale and water-side fouling, feedwater and water-treatment faults, and control or sensor failures. Every one of them is a scheduled maintenance item before it is an emergency — which is why a service agreement costs less than the outage it prevents.
Report a breakdownMaintenance designed to improve performance and reduce costs
Regular service reduces energy waste, prevents breakdowns and ensures steam reliability—all critical for industrial operations.
Benefits:
Better fuel efficiency: Our tune-up and combustion optimisation service restores peak thermal efficiency, often recovering 5–15% in fuel savings immediately.
Improved safety: Regular safety checks, pressure vessel inspections, and compliance audits ensure your plant meets AS/NZS and state WorkSafe requirements.
Longer boiler lifespan: Preventive maintenance programs extend equipment life beyond OEM projections, protecting your capital investment over the long term.
Predictable maintenance costs: Fixed-price service agreements give you budget certainty and priority access to our national team of qualified boiler engineers.
Service level options
Compare service plansEssential
Stay compliant, safe and serviced.
- Annual statutory inspection & compliance certification
- 1 preventative maintenance visit per year
- Combustion tune-up & efficiency check
- Steam-trap & safety-valve inspection
- Business-hours phone & email support
Recommended
Performance
Maximise uptime and fuel efficiency.
- Everything in Essential, plus:
- 2 maintenance visits per year
- Condition monitoring & efficiency reporting
- Priority breakdown response
- Annual combustion optimisation
- Spare-parts discount
Premium
Full lifecycle peace of mind.
- Everything in Performance, plus:
- Quarterly maintenance & full lifecycle support
- 24/7 emergency response with guaranteed SLA
- Dedicated account engineer
- Remote & predictive monitoring
- Fixed-price budget certainty
Compare service plans
| Service feature | Essential | Performance | Premium |
|---|---|---|---|
| Statutory inspection & compliance | ✓ | ✓ | ✓ |
| Preventative maintenance | 1 / year | 2 / year | Quarterly |
| Combustion service | Tune-up | Optimisation | Optimisation |
| Condition monitoring & reporting | — | ✓ | Remote + predictive |
| Breakdown response | Standard | Priority | 24/7 SLA |
| Technical support | Business hours | Business hours | Dedicated engineer |
| Spare-parts discount | — | ✓ | ✓ |
| Fixed-price budget certainty | — | — | ✓ |
Frequently asked questions
How often should a commercial boiler be serviced in Australia?
There is no single national interval — it depends on duty, fuel, insurer requirements and the standard the boiler operates under. Industrial boilers on continuous duty are commonly serviced quarterly with a full annual inspection and shutdown, and boilers certified for unattended operation carry their own inspection schedule under AS2593. O'Brien sets the interval in a tailored service agreement; the two OBYONE steam boilers at Lion's Perth brewery, for example, run on a three-monthly service.
What should I do when a boiler breaks down?
Isolate the unit safely, record the alarm or lockout code, protect production with a standby or hire unit, then call a qualified technician. Do not reset a lockout before the cause is known.
Do you offer 24/7 emergency boiler repairs?
Yes. O'Brien provides a 24/7, 365-day nationwide breakdown response, with parts on hand and gaskets manufactured in-house. Attendance times vary with site location and access — we confirm them when you call.
Can we keep producing while the boiler is repaired?
Often, yes. Shedding non-critical steam load, switching to a standby unit or bringing in a temporary hire boiler keeps production running through a longer repair. Raise it on the first call so the option is set up in parallel with the repair, not after it.
What does a boiler service include?
A scheduled service covers safety and control device testing, combustion tuning, water-side and fire-side inspection, water-treatment checks and a written report against Australian Standards. Scope scales with the service level — the Essential, Performance and Premium plans above set out what each one covers.
Protect your equipment and improve system performance
Book a Service AssessmentCase Studies
Proven results in the field
ManufacturingCalfors Bruk
Calfors Bruk — Sweden
~600k SEK saved yr 1 . 90 °C output
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Food ManufacturingPrimo
Primo — Chullora
12 MW added . live plant . 5–10% energy saved
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BeverageLion
Lion — Perth Brewery
2 × 500 kW added . live plant . 5 months
Read case study →
Food ManufacturingReal Pet Food
Real Pet Food — Yatala
28.5% less gas . ~$45K/month saved
Read case study →