Severe Scaling on Low-Pressure Steam Boiler Voted as ‘Scariest’
In the fall 2023 edition of the BULLETIN, we introduced "Scary Photos," a feature showcasing the hazards National Board Commissioned Inspectors encounter during routine inspections. These photos serve as a stark reminder of what to watch for in the field, highlighting the critical role of vigilant inspections in ensuring safety.
This is the second year we held a vote on the “scariest” photo. Submissions were from the fall 2024, spring 2025, and summer 2025 editions. The inspector behind the winning submission received a $100 gift card. While the contributors remain anonymous to protect privacy, we’re excited to share the winning entry.
WINNING SUBMISSION
Upon inspection of this low-pressure steam boiler, the waterside showed severe scaling up to a half inch. A snake camera with an articulating head was used to view the lower tubes. The second row of tubes showed bridging taking place, and a little lower, complete bridging was evident. The furnace tube had a huge bulge on the fireside, and you couldn’t see through the second pass tubes. There was little to no water circulation in the boiler. It is a miracle the boiler did not relocate itself. A boiler repair company did a total tube replacement and added new tube sheets. The furnace bulge was cut out and weld-repaired, and an AI inspection was performed with hydro testing. The boiler was down for about two weeks.
Do you have a “Scary Photo” to share? Submit a high-resolution image (at least 300 dpi) and a brief description of the issue and the corrective actions taken. Please ensure submissions do not include identifiable details about specific people or locations.
Send your photo and description to Lee Cochran, senior editor, at lcochran@nbbi.org.
Our next vote will be this fall.
Your contributions help shine a light on the challenges faced in the field and remind us all of the importance of safety and diligence.