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A Boiler: The Explosive Potential of a Bomb
Acoustic Emission Examination of Metal Pressure Vessels
Anatomy of a Catastrophic Boiler Accident
Austenitic Stainless Steel
Auto-Refrigeration
Basic Weld Inspection - Part 1
Basic Weld Inspection - Part 2
Black Liquor Recovery Boilers - An Introduction
Boiler Efficiency and Steam Quality: The Challenge of Creating Quality Steam Using Existing Boiler Efficiencies
Boiler Logs Can Reduce Accidents
Boiler/Burner Combustion Air Supply Requirements and Maintenance
Carbon Monoxide Poisoning Preventable With Complete Inspection
Combustion Air Requirements:The Forgotten Element In Boiler Rooms
Creep and Creep Failures
Description of Construction and Inspection Procedure for Steam Locomotive and Fire Tube Boilers
Ensuring Safe Operation Of Vessels With Quick-Opening Closures
Environmental Heat Exchangers
Factors Affecting Inservice Cracking of Weld Zone in Corrosive Service
Failure Avoidance in Welded Fabrication
Finite Element Analysis of Pressure Vessels
Fuel Ash Corrosion
Fuel Firing Apparatus - Natural Gas
Grain Boundaries
Heat Treatment - What Is It?
How to Destroy a Boiler -- Part 1
How to Destroy a Boiler -- Part 2
How to Destroy a Boiler -- Part 3
Identifying Pressure Vessel Nozzle Problems
Inspection, Repair, and Alteration of Yankee Dryers
Inspection, What Better Place to Begin
Laminations Led to Incident
Lay-up of Heating Boilers
Liquid Penetrant Examination
Low Voltage Short Circuiting-GMAW
Low Water Cut-Off Technology
Low-Water Cutoff: A Maintenance Must
Magnetic Particle Examination
Maintaining Proper Boiler Inspections Through Proper Relationships
Microstructural Degradation
Miracle Fluid?
Organizing A Vessel, Tank, and Piping Inspection Program
Paper Machine Failure Investigation: Inspection Requirements Should Be Changed For Dryer Can
Pipe Support Performance as It Applies to Power Plant Safety and Reliability
Polymer Use for Boilers and Pressure Vessels
Pressure Vessel Fatigue
Pressure Vessels: Analyzing Change
Preventing Corrosion Under Insulation
Preventing Steam/Condensate System Accidents
Proper Boiler Care Makes Good Business Sense:Safety Precautions for Drycleaning Businesses
Putting a Stop to Steam Kettle Failure
Quick Actuating Closures
Quick-Actuating Door Failures
Real-Time Radioscopic Examination
Recommendations For A Safe Boiler Room
Recovering Boiler Systems After A Flood
Rendering Plants Require Safety
Repair or Alteration of Pressure Vessels
Residential Water Heater Safety
School Boiler Maintenance Programs: How Safe Are The Children?
Secondary Low-Water Fuel Cutoff Probe: Is It as Safe as You Think?
Short-Term High Temperature Failures
Specification of Rupture Disk Burst Pressure
Steam Traps Affect Boiler Plant Efficiency
Steps to Safety: Guide for Restarting Boilers after Summer Lay-Up
Stress Corrosion Cracking of Steel in Liquefied Ammonia Service - A Recapitulation
Suggested Daily Boiler Log Program
Suggested Maintenance Log Program
System Design, Specifications, Operation, and Inspection of Deaerators
Tack Welding
Temperature And Pressure Relief Valves Often Overlooked
Temperature Considerations for Pressure Relief Valve Application
The Authorized Inspector's Responsibility for Dimensional Inspection
The Effects of Erosion-Corrosion on Power Plant Piping
The Forgotten Boiler That Suddenly Isn't
The Trend of Boiler/Pressure Vessel Incidents: On the Decline?
The Use of Pressure Vessels for Human Occupancy in Clinical Hyberbaric Medicine
Thermally Induced Stress Cycling (Thermal Shock) in Firetube Boilers
Top Ten Boiler and Combustion Safety Issues to Avoid
Typical Improper Repairs of Safety Valves
Wasted Superheat Converted to Hot, Sanitary Water
Water Maintenance Essential to Prevent Boiler Scaling
Water Still Flashes to Steam at 212
Welding Consideration for Pressure Relief Valves
Welding Symbols: A Useful System or Undecipherable Hieroglyphics?
What Should You Do Before Starting Boilers After Summer Lay-Up?
Why? A Question for All Inspectors


Suggested Maintenance Log Program


Summary: The following article is a part of National Board Classic Series.

 


 

The following maintenance items, as appropriate to the specific boiler system, need to be considered for implementation on a regular basis (e.g., daily, weekly, monthly, semiannually, annually). A checklist of the items should be incorporated into a maintenance log with provisions for checking off the item for the appropriate period. A separate log sheet is suggested for each period. The log sheets can be filed in a loose-leaf binder, and should be retained as a permanent maintenance record.

The log sheets can be used as a handy check-off system when establishing a facility maintenance program. In all cases the equipment manufacturer's recommendations should be followed.

DAILY

  • Blow down and test low water cutoffs of steam boilers (once per shift for high pressure)
  • Blow down gage glasses (steam)
  • Blow down make up feeder (low pressure steam)
  • Blow down boiler (steam)
  • Check boiler contraol linkage
  • Check boiler and system for leaks
  • Check burner flame

WEEKLY

  • Check compressor(s) lubricating oil level (control and atomizing)
  • Check flame signal strength for both pilot and main flame, and record readings
  • Check flame failure cutoff and timing
  • Check pilot and main flame fuel shutoff valve closing
  • Check ignitor and burner operation
  • Check level in chemical treatment tank

MONTHLY

  • Check compressor(s) air filter, and clean or replace as required
  • Check boiler water treatment test results received from treatment company, adjust treatment as required
  • Lubricate motor and equipment bearings
  • Test fan and air pressure interlocks
  • Check main burner fuel safety shutoff valves for leakage
  • Check low fire start interlock
  • Check high pressure/temperature interlocks
  • Test low water cutoffs (hot water)
  • For oil -- test pressure and temperature interlocks
  • For gas -- test high and low gas pressure interlocks
  • Manually lift safety/safety relief valves and check operation

SEMIANNUALLY

  • Inspect burner components
  • Check flame failure system components
  • Check piping and wiring of all interlocks and shutoff valves
  • Recalibrate all indicating and recording gages and instruments
  • Perform a slow drain test for low water cutoffs (steam)
  • Check combustion control system
  • For oil -- check atomizers and strainers
  • Test boiler safety/safety relief valves in accordance with ASME Boiler and Pressure Vessel Code, Sections VI and VII

ANNUALLY

  • Perform the SEMIANNUAL maintenance procedures
  • Check all equipment coils and diaphragms
  • Perform a pilot turndown test
  • Recondition or replace low water cutoff
  • For gas -- check drip leg and gas strainer
  • Clean boiler firesides
  • Drain boiler, open manholes and hand holes, and clean watersides
  • Have boiler inspected by a commissioned inspector
  • Clean burner and gans
  • Replace gaskets
  • Leak-test all fuel valves
  • Test operation of all controls and safety devices
  • Have fuel-burning system adjusted using combustion test instruments

AFTER EACH PERIOD

  • Make a record of all maintenance and parts replacement in the maintenance log

 


 

Editor's note: Some ASME Boiler and Pressure Vessel Code requirements may have changed because of advances in material technology and/or actual experience. The reader is cautioned to refer to the latest edition of the ASME Boiler and Pressure Vessel Code for current requirements.

 







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