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