DURAG Repair Services India
DURAG is a German leader in combustion process control and emission monitoring systems, founded in 1947. Specializing in O2 sensors, flame scanners, and burner management systems for power generation, petrochemical, and industrial heating applications globally. DURAG equipment is widely deployed across Indian refineries, thermal power plants, and steel mills where precision flame supervision and exhaust gas analysis are critical for safety and regulatory compliance.
DURAG is a German leader in combustion process control and emission monitoring systems, founded in 1947. Specializing in O2 sensors, flame scanners, and burner management systems for power generation, petrochemical, and industrial heating applications globally. DURAG equipment is widely deployed across Indian refineries, thermal power plants, and steel mills where precision flame supervision and exhaust gas analysis are critical for safety and regulatory compliance.
Synchronics has repaired DURAG combustion control systems since 1994, with extensive expertise across 11 product lines including flame safeguard modules, oxygen trim systems, and gas analyzer units. Our 180+ engineers understand DURAG's proprietary sensor interfaces, signal conditioning circuits, and firmware protocols. We offer rapid turnaround on DURAG faults, preventive maintenance contracts for critical boiler systems, and genuine component sourcing — making us the trusted DURAG repair partner for Indian power utilities, refineries, and process industries.
DURAG flame supervision and combustion control system specialists across India.
DURAG Equipment We Repair — By Category
DURAG Product Lines We Repair
Our engineers are trained on the full DURAG product range. Below are the major product families we service.
DURAG Flame Safeguard Scanners
UV and infrared flame detection modules used in boiler ignition safety systems. Common faults include UV tube degradation, signal loss, and optical lens fouling in dusty industrial environments. Synchronics performs complete sensor recalibration and photomultiplier tube replacement.
DURAG Oxygen Trim & Combustion Control
Automated O2 analyzer systems for fuel-air optimization in furnaces and boilers. Frequent failures include zirconia sensor poisoning, reference air line blockages, and signal conditioning amplifier drift. Synchronics provides sensor replacement, calibration certification, and circuit board repair.
DURAG Burner Management Systems
Logic controllers and relay modules for sequential burner startup and shutdown. Issues include relay chatter, capacitor leakage on PCBs, and firmware corruption. Synchronics rebuilds control modules and flashes firmware from DURAG specifications.
DURAG Flue Gas Analysis Probes
Extractive and in-situ gas sampling systems for NOx, SO2, and CO monitoring in power and refinery stacks. Common wear includes sample line corrosion, cooler blockages, and analyzer calibration drift. Synchronics cleans probe assemblies, replaces sample conditioning components, and performs multi-point calibration.
DURAG Signal Conditioning & Transmitters
Analog and digital signal processors for flame scanner outputs and sensor signals in harsh boiler room environments. Failures include input amplifier saturation, 4-20mA loop instability, and connector corrosion. Synchronics replaces passive components, recalibrates output circuits, and tests all signal ranges.
DURAG Emission Monitoring Software & Display Units
Local HMI panels and SCADA interfaces for real-time combustion visualization and trend logging. Hardware faults include LCD failure, keypad membrane wear, and backup battery depletion. Synchronics repairs display modules, updates software, and provides data recovery services.
Why Choose Synchronics for DURAG Repairs?
PCB-Level Expertise
We repair down to the component level — not just swap boards. Our engineers identify root causes, replace failed IGBTs, capacitors, processors, and gate drivers on DURAG equipment.
Fast Turnaround
Standard 7–10 working days. Express 3–5 days available for critical breakdowns. Emergency same-day/next-day service for unplanned downtime.
6-Month Warranty
Every repaired unit ships with a 6-month comprehensive warranty on parts and labour. Our repair success rate is over 94% across all brands.
All-India Service
Couriered repairs accepted from any city in India. Doorstep pickup available in Vadodara, Mumbai, Pune, Ahmedabad, Surat, Chennai, and more.
Common DURAG Equipment Faults We Fix
Based on 30+ years of repair data, these are the most frequent failure modes we see in DURAG equipment arriving at our workshop.
- ✓Flame scanner loses signal intermittently in operation — DURAG UV tube has degraded output or optical window is fouled by boiler ash, soot, and combustion byproducts. In Indian coal-fired power plants with high ash carry-over, this is a frequent field issue occurring every 12-18 months.
- ✓O2 sensor reads erratic values; trim loop oscillates wildly — DURAG zirconia O2 sensor has become poisoned from lead or silicone contamination in fuel oil, or the reference air sample line is partially blocked by ice in winter or mineral deposits in humid coastal refineries. Signal conditioning amplifier may also have drifted due to component aging.
- ✓Burner management system resets unexpectedly; burners shut down without cause — Relay coils in the DURAG BMS logic module have developed chatter or contacts are eroded from high switching frequency, or firmware has become corrupted due to power surges common in Indian industrial areas with unstable grid supply.
- ✓CEMS probe shows rising baseline; analyzer no longer zeros properly — DURAG sample conditioning system has accumulated moisture and mineral deposits from the flue gas. In Indian refineries with high sulfur fuel oil, sulfuric acid aerosol can corrode sample lines and cooler tubes, degrading zero calibration and span linearity.
- ✓Signal transmitter output stuck at 20mA or shows no output; 4-20mA loop is broken — DURAG TW-series signal conditioning module has failed input amplifier stage or output driver transistor, often caused by loose connections allowing moisture ingress in coastal areas. Connector pins may be corroded from salt spray or boiler steam leaks.
- ✓HMI display panel is blank; backlight works but no text or trend data visible — DURAG EMS 3000 display LCD has developed pixel failure or internal connector has lifted due to thermal cycling in boiler room temperature extremes. Software corruption can also prevent display initialization if power was lost during update.
How We Repair Your DURAG Unit
Receive & Log
Your unit is logged into our tracking system with a unique job number. You receive WhatsApp / email updates at every stage.
Fault Diagnosis
Board-level diagnosis using oscilloscopes, LCR meters, and thermal cameras. Root cause identified before any repair begins.
Component Repair
Faulty ICs, capacitors, MOSFETs, IGBTs, and gate drivers replaced with genuine or equivalent-spec components.
Full-Load Test
Unit tested under rated load with original or equivalent motor. All parameters verified. 6-month warranty issued.
Industries Using DURAG Equipment
We serve plant maintenance teams across all major industries where DURAG automation is deployed.
Frequently Asked Questions — DURAG Repairs
Do you repair DURAG equipment anywhere in India?+
Yes. Synchronics repairs the complete DURAG product range - flame scanners, O2 sensors, burner management systems, CEMS probes, signal transmitters, and HMI display units. We offer PAN India door pickup service from Mumbai, Delhi, Pune, Kolkata, Chennai, Hyderabad, Ahmedabad, Surat, and all other industrial cities. All repairs are performed at our main facility in Vadodara, Gujarat, where we maintain DURAG spare parts inventory and calibration equipment.
How long does a DURAG flame scanner repair typically take?+
Standard DURAG flame scanner repair including UV tube replacement, optical cleaning, and recalibration typically takes 3-5 working days from receipt. If only optical cleaning is needed, turnaround can be 1-2 days. We offer express service for critical power plant shutdowns - contact our emergency repair hotline for priority handling. All scanners are tested under simulated flame conditions before dispatch.
Can Synchronics recalibrate DURAG O2 sensors and provide ISO certificates?+
Absolutely. Synchronics performs DURAG oxygen sensor recalibration using certified reference gas standards traceable to NPL India standards. We execute 3-point or 5-point calibration as per your application, generate ISO 17025 calibration certificates, and provide data sheets showing before/after sensor performance. These certificates are accepted by Indian power plant regulatory auditors and refinery quality systems.
What is the most common DURAG failure we see in Indian thermal power plants?+
UV flame scanner signal loss is the most frequent DURAG fault we repair in Indian coal-fired power stations. High ash carry-over, poor combustion conditions, and lack of regular optical cleaning cause UV tubes to degrade rapidly in dusty environments. Our preventive maintenance program recommends scanner inspection every 6-12 months with optical cleaning and photomultiplier tube testing. Early intervention prevents unexpected boiler trips that can cost thousands in lost generation.
Do you stock genuine DURAG spare parts or use aftermarket alternatives?+
Synchronics prioritizes genuine OEM DURAG parts for all repairs - UV tubes, zirconia sensors, relay modules, LCD displays, and connector assemblies. We maintain inventory relationships with DURAG distributors and can source hard-to-find legacy components for older systems still running in Indian plants. For non-critical passive components (capacitors, resistors), we use industrial-grade equivalents from reputable suppliers if OEM parts are unavailable. All part selections are documented in your repair report.
How do I send my DURAG unit for repair?+
Pack the unit securely and courier it to our Vadodara workshop. Include a note with the fault description and your contact details. We will log it into our system and WhatsApp you a job number within 24 hours of receipt. Doorstep pickup is available in Vadodara, Ahmedabad, Surat, Mumbai, and Pune.
What is the cost of repairing a DURAG drive or PLC?+
Repair cost depends on the model and the fault. We offer a free diagnosis — once we identify the fault, we provide a fixed quotation before proceeding. Typical repairs cost 20–40% of the new unit price. We will never repair without your approval.
What warranty do you provide on DURAG repairs?+
All repaired units carry a 6-month comprehensive warranty covering the same fault and related issues. If the fault recurs within the warranty period, we repair it free of cost.
Do you provide a no-fix, no-fee guarantee?+
Yes. If we cannot repair your DURAG unit after diagnosis, you pay only the diagnosis fee (₹500–₹1,500 depending on the product). The unit is returned to you at no additional charge.
DURAG Repair Catalog
Showing 1–12 of 12 DURAG products
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Send us your faulty industrial electronics. Our engineers will diagnose it and provide a detailed quote within 24 hours — with no obligation to proceed.
Free Evaluation
No obligation
48hr Turnaround
Fastest in India
6-Month Warranty
Every repair
No Fix, No Charge
Zero risk policy
Pan-India Pickup
Doorstep service