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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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