This service includes the preparation of boilers for statutory inspections, re-tubes and burner and stoker repairs, as well as on- or off- site conversions from/to oil, gas and coal. Our service teams also handle recommendations regarding maintenance and service contracts for trouble-free running of plant.

As a leader in the field of boiler technology, we have extensive materials engineering facilities for both in-plant and on-site investigations. These facilities enable detailed investigations to be conducted to establish the metallurgical condition of materials and failure analysis. The methods involved range from hardness inspections and thickness checks to detailed metallographic examination using replication techniques.

We overhaul and install second-hand boilers of all types, makes and sizes, backed by in-house engineering, manufacturing and site installation facilities to ensure that the end product will offer a safe and reliable long working life.

In addition to supplying standard boilers, we project manage and engineer large turnkey boilerplant installations which include civil, electrical, instrumentation, fuel and ash handling flue-gas clean-up and pre-boiler plant. The project management objectives of directing and co-coordinating human and material resources throughout the life of the project are achieved by utilising modern management techniques to cover the predetermined objectives of scope, cost, time, quality and participant satisfaction. A project manager is appointed for each project and has responsibility for the overall management of the project.

A full range of Original Equipment Manufacturer (OEM) spares is available for all John Thompson boilers, stokers and other ancillary equipment. A large proportion of cast spares are produced in our own foundry near Cape Town, which is licenced to produce all castings under the Meehanite process. It is the only foundry in South Africa dedicated solely to boiler castings.

We purchase used John Thompson boilers from industries which are installing new boilerplant, have excess capacity or are closing down. As the OEM, we then carry out a full engineering program on the used boilers which allows for replacement of all combustion equipment and components as well as upgrading where the latest technologies can be implemented. Original drawings and certificates are held at our head office for all boilers manufactured by us, ensuring that the boilers can be remanufactured to a standard that carries the John Thompson guarantee. Stringent quality control under the ISO 9001 quality management system ensures that a John Thompson remanufactured boiler will provide many more years of safe, reliable operation.

Extensive facilities are available for metallurgical evaluation of materials and failure analysis for both in-plant and on-site investigations. The facilities, directed by our resident metallurgist, range from hardness inspections and thickness checks to detailed metallographic examination using replication techniques. Replication techniques involve on-site non-destructive examination of metal structures and are indispensable tools in the life assessment of equipment and subsequent decisions on extending that life. Materials testing facilities at our Bellville Works enable detailed failure analyses to be carried out using the latest laboratory techniques. These can pin-point micro defects in materials which would otherwise be undetected.

Our energy management department was formed to meet the need of customers' outsourcing their non-core business. By entering into an energy management contract, customers will be relieved of the responsibility, for example, of the generation of steam and the operating and maintenance of all associated plant. The cost-efficient supply of steam can be applied to existing or new boilerplant through a choice of contract options, such as: The supply of steam on a rands per ton basis using the customer-owned boilerhouse, where John Thompson assumes full responsibility for the purchase of fuel, operation and management of boiler plant and steam supply. The supply of steam on a rands per ton basis using a new financed boilerhouse with full John Thompson responsibility for boiler plant supply, installation and operation. The supply of competent boiler operators. We also offer steam utilization surveys and feasibility studies.

The Boiler Development & Training Centre at our Bellville site provides the skills required for the efficient operation of modern boilerplant. The following courses are available: A ten-day coal-firing course for boiler attendants, boilerhouse supervisors and standby or emergency personnel A five-day oil- and gas-fired boiler operation and maintenance course for boiler operators, boilerhouse supervisors, maintenance supervisors and standby personnel A three-day stoker maintenance course for boilerhouse supervisors, maintenance managers, foreman and fitters A five-day boiler maintenance course for boilerhouse supervisors, maintenance managers, foremen and fitters A five-day boiler supervision and management course for factory managers, engineers, boiler supervisors and maintenance managers A five-day inspection course for competent persons (boilers), maintenance engineers, maintenance foremen and experienced boilerhouse fitters On-site courses for customers who want specific training on their own plant