External Inspection (Continued)

Leaks: Chemical control, excessive make-up rate, increase corrosion rates.

Indicating devices: Gages & glass, thermometer.
Safety Devices: Cutoffs, low water level alarms, burner failure alarms and
safety valves. Label - of last test date & pressure rating.
Control System: Kept clean and free moving no external electrical safety
hazards.
Valves: Clean and free from leakage.
Housekeeping: Kept clear of combustible materials. Oil, grease and or
chemicals.
Signs: All accesses to boiler rooms are to be labeled High Noise Area
Hearing Protection required.
Piping Supports: Positive support ensure no shifting or loose support
brackets.

General Test Procedures

Safety / Relief Valve Operational Test (Document Monthly) All safety

valves are to be tested in place each month by using the test level provided.
With boiler pressure at least 75% of safety valve set point, fully open the
Safety / Relief Valve and let it snap shut. If the valve does not reseat properly,
repeat the test. If the Safety / Relief valve cannot be lifted, the boiler
must be shutdown immediately until the valve can be repaired or
replaced. NOTE: Excessive hand lifting will shorten the life of the valve.
Prior to installation in a boiler system, all safety valves shall be inspected, set
and tested by a qualified valve repair shop. The shop should provide
documentation of the inspection and methods used to set and test the safety
valve.
Check System for Leaks (Document Weekly) the entire system is to be
checked closely for leaks daily and documented weekly. Particular attention
should be paid to pump and valve packing, automatic air vents, and
condensate tank overflow lines. Excessive leaks will result in excessive
corrosion & scale buildup in the boiler and result in shortened boiler life.
Low Water Fuel Cutoff (LWFCO) Rapid Drain Test (Document Weekly &
on Startup) With the burner in operation, rapidly flush the LWFCO chamber
using the drain valve provided. The burner must shut off when the device is
drained. If the boiler does not have at least one properly functioning
LWFCO, it must not be left unattended, while operating, until repairs
are made. ENSURE VISUAL AND AUDIBAL ALARMS FUNCTION PROPERLY.

Burner Check (Document Monthly) Observe the boiler and burner for a
long enough period to be certain that the burner operates normally. Test the
Combustion Safeguard System.
Water Chemistry Check (Document Monthly) Ensure contracted vender
has conducted proper water chemistry checks and provided support
documents. Conduct action recommended on report to maintain proper
chemistry
LWFCO slow Drain Test (Document Quarterly) with the burned in
operation, verify the function of the LWFCO by slowly reducing the level of the
water in the boiler. Great care must be taken to prevent actually firing the
boiler with insufficient water.
Condensate Pump Check (Document Quarterly with the LWFCO Test)
When conducting the LWFCO test, verify operation of the condensate pump
and / or emergency feeder.
Safety Valve Setpoint Test (Document Annually) Safety and relief valves
are to be tested annually to ensure they are set correctly and are in proper
operational condition. Normally this can be accomplished while he boiler is
shutdown for annual internal inspection.
Drain Water Gage Glass (As necessary) Danger: Possibility of escaping
hot water / steam can cause burns. If necessary, to remove suspended or
floating impurities, drain and flush the water column and gages glass by
shutting the top and bottom isolation valves of the gage glass then slowly
crack open gage glass drain. Shut gage glass drain after water column has
drained. Slowly open upper gage glass isolation valve then slowly open lower
gage glass drain. Water level should immediately rise in the gage glass.

Operating Parameters
Boilers operated in the proper ranges will help ensure the mechanical integrity and
life of the unit.
pH: low pH = rust, high pH = causes pitting.
Stack Temperature: Kept between 300 & 400 degrees (depending on boiler
load), high temp indicates efficiency significantly reduced.
Steam Pressure: Should never exceed 150 psi, except during pressure lift
check of safety valves.
Chemicals: Boiler chemicals are caustic, require PPE, clean-up spills when
they happen, review MSDS before handling, trained personnel only.
Maintenance
Replacement parts must comply with manufactures proper rating.
Improper materials = explosion or rupture.

 Lockout / Tagout, Confined Space Entry, Electrical Safety & Hot Work
Procedures will be followed at all times.
Thermal energy must be dissipated prior to starting work.
Valves: Before making packing adjustments depressurize system.
Pumps: Packing adjustments, pump running, one flat at a time, leakage
minimum 2 drops maximum 6 drops per second. Over tightening can cause
pump shaft sleeve damage.
Gaskets: Always install new gasket material when mechanical joints have
been disassembled. Never reuse old gaskets.
Pre-Startup & Automatic Shut-down Checks Match-up
Procedures:
1. Prior to firing a boiler?
2. Extended shutdown 12 to 24 hours.?
3. Daily Checks?
4. Automatic Boiler Shutdown?

Check when ?
A. Leakage of water, steam, fuel.
B. Wet thermal insulation.
C. Per-start-up check.
D. Pipe supports alignment and condition.
E. Clean & free combustible material.
F. Extended shutdown.
G. Flame Out Shutdown device.
H. Gages, thermometers.
I.

Low Water Level Alarm.

SOP Preparations and Safety Precautions for Internal Inspection

Annual internal inspection of pressure vessels by a licensed inspector.
-

Water level remains at normal operating level until the unit has
been cooled down.

Fast cool down can cause cracking or damage to boiler casing,

tubes & welds.

Ensure safe conditions exist for the inspection.

-

Confined Space Entry procedures are followed.

Fuel turned off.
Power turned off.

Dont embarrass your self in-front of the OSHA inspector.

Lock & Tagout the fuel supply and ignition systems.
Shut, lock & Tagout all system isolation valves for steam, gas, water and feed
systems.
Draw off all water and thoroughly washout the waterside.
-

Drain valves or cocks between two closed valves before opening

manholes.
All drains & vent valves must be open.
Alternative lines may be blanked or sections of pipe removed.

Remove manhole and hand-hole plates, washout plugs, inspection plugs as

may be required by the inspector.
Remove grates, insulation / brickwork to determine condition of boiler,
headers, furnace, supports etc
Remove pressure gages for testing, open fireside doors and ventilate before
Confined space Entry.

Records
Inspection records are to be maintained on file permanently.
Repair and Maintenance records are to be maintained on file permanently.
Weekly / monthly Boiler Inspection records (self-inspection) are to be sent to
BSE office and maintained permanently.
Safety Device Tests / Check records are to be maintained for one year on
most recent basis.
Safety Valve Certification records, provided by a valve repair shop,
maintained on most recent basis.