Name: Henry O. Mondragon Jr.

Score/Mark:

Year and Section: MarE-3GOLF Date: 06/12/2021

LEARNING ACTIVITY NO.13

Course Power Plant Steam

Topic Inspection and Safety checks

Learning Outcome(s) Conduct inspection and safety checks on a boiler system

Instructor C/E Rodel P. Gudian

LESSON MAP

I.

Inspection and Safety checks to Marine

Steam Boiler

Inspection to Marine Steam

Safety checks to Marine Steam Boiler
Boiler

INSPECTION TO MARINE STEAM BOILER

Boiler Maintenance Checklist

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 A Scotch-marine steam boiler, common in residential buildings,
typically lasts 25 to 30 years with proper maintenance.
Following a regular maintenance schedule for your building's boiler plant will go a long way
toward minimizing breakdowns and service interruptions. Here are some key items that should
be a part of any building's operational plans. 

Annual Maintenance

These maintenance items should be done once a year by a heating contractor between heating
seasons (June to September): 
 Inspect and clean fireside surfaces.
 Inspect all burner refractory material.
 Inspect all manhole gaskets for leaks.
 Inspect and test all system valves.
 Inspect and test all safety valves.
 Clean and rebuild low water cut-off.
 Recalibrate all operating controls.
 Overhaul feed water pumps.
 Clean condensate receiver.
 Inspect electrical terminals.
 Switch boiler automation to summer mode.
 Check fuel oil levels.
 Clean and inspect chimneys.
 Clean and tune boiler and components. 
 

Periodic Maintenance

These items should be addressed by the building's maintenance staff on a continual basis, or
as often as indicated below:
 Check and maintain proper oil level in compressor lube tank (daily). Use SAE 20/30 oil.

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 Clean oil filters at least twice a week:
- Shut-off power to pump motor.
- Close shut-off valve.
- Pull out filter. Clean filter and re-insert into housing.
- Place strainer cap into proper position, restart pump motor, and check vacuum.
- Vacuum reading must be high; if not, check seal on cap. If reading is high, then open oil
valve.
- Check oil pressure reading at the burners.
 Keep sight glasses clean. This allows for a clear view of the burner flame and any carbon build-
up on the boiler's combustion chamber (as needed).
 Keep air filters clean. A clogged air filter can lead to poor air/oil mixture and carbon build-up
(as needed).
 Check oil circulation temperature at sidearm pre-heaters. Inlet temperature should be 110° F to
120° F, and outlet temperature should be 140° F to 150° F for No. 6 oil (daily).
 Flush drain low water cut-offs/sidearm oil pre-heater (twice a week).
 Flush drain low water cut-offs while burner is on and a flame is present in the boiler's
combustion chamber. When the unit is flushed, the flame should turn off. Allow the burner to
start before checking other low water cut-offs.
 Flush down water-line heater, shut off lower isolation valve, open drain valve to flush unit, shut
drain off valve, and reopen isolation valve. 
 Conduct boiler bottom blowdown to clear sludge and sediment, control high water, and control
chemical treatment concentrations (monthly or as needed).
 Monitor the make-up water being added to the boiler and/or the boiler feed unit. Since the
system operates via closed loop, an excess amount of fresh (untreated, oxygenated) water
supply is detrimental to boiler components and is often a sign of a leak in the system. 
 Monitor smoke alarm on a weekly basis:
- Wipe light source and receiver.
- Smoke alarm unit should not be set at its highest point.
- Unit should be set in accordance with NYC Buildings Department standards.
 Maintain a rigorous boiler chemical feedwater treatment program. 
 Maintain a boiler room log to record any problems and routine maintenance.
 Check combustion, inspect burner controls, and inspect burner operation.
 Conduct trap inspection program with replacement of trap elements in apartment units and
steam traps within the cellar.
 Conduct pipe inspection program to ensure all pipes are pitched in the direction of steam source
(one-pipe steam systems) or condensate drainage (two-pipe systems).

II. SAFETY CHECKS TO MARINE STEAM BOILER

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Boiler Room Checklist at Startup

As we previously mentioned, a large number of explosions originate during shutdown and

startup. Use the following boiler startup checklist to improve boiler room safety:

 Make sure to verify water level in boiler.

 Inspect all manual and automatic controls regulating feed water, dampers draft, as well as
interlocks.
 Make sure every stack damper is open.

 Inspect flame detection equipment.

 Check flue passes and the furnace for fuel accumulation. Make sure all unburned fuel is
thoroughly removed.

 Make sure you fully clear gas passages by purging furnace for a minimum of three to five
minutes.

 Anytime your burner doesn't ignite within five seconds, make sure you turn off the fuel
supply and repurge the furnace.

 Never leave your boiler on auto fired while unattended once you have started it — until it
has successfully completed multiple firing cycles and you've verified that all controls are
properly functioning.

Monthly Boiler Room Checklist 

In addition to the previously mentioned items, you can help improve boiler room safety by
conducting the following monthly tests and checks:

 Inspect the air flow interlocks and fan

 Check the flame failure detection system
 Inspect the temperature interlock or high steam pressure

 Check the low fire start interlock

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 Inspect temperature interlocks and fuel pressure

 Check drip leg and gas cleaner

 Test low and high fuel pressure interlocks

III. Student Additional Activity

III-A. Watch the video #13: MARINE BOILER CHECKS AND INSPECTIONS

1. (https://www.youtube.com/watch?v=Mc5qZ-BC_Kk)
2. Make a summary of MARINE BOILER CHECKS AND INSPECTIONS discussed
on the video. Write your summary below. Please write legibly
____ The boiler maintenance should always be executed with skill and in accordance
with valid rules and regulations from the authorities. Below some recommendations
are given for periodical inspections and maintenance. Daily normal operation of the
boiler, some work and check procedures have to be considered every day. First is to
Check the boiler steam pressure and the water level. Second is to Check that the feed
water control system is operational see separate instructions. Third is to Check the
boiler water condition and inquire necessary countermeasures with regard to the feed
and boiler water treatment. If necessary, blow-down the boiler. Fourth is to Check the
function of the oil burner at different capacities through the inspection holes on the
boiler. Fifth is to Check the flue gas temperature after and or the draft loss across the
boiler. If either the temperature or the draft loss is too high the smoke tube section, for
the oil fired as well as the exhaust gas part, must be cleaned. The weekly check is to
Drain each water level glass for about 10-15 seconds. In case of contaminated boiler
water sufficient water treatment, the draining of the water level glasses must be done
more often. Second is to Check the safety water level device and third is depending on
the boiler water tests, blow-down the boiler. Open the blowdown valves quickly for a
few seconds, and then close and open for about 5-10 seconds. Repeat this operation
when required according to the boiler water tests. Fourth is to perform scum blow out
by means of the scum valve when required. The scum blow out must be carried out
until the drained water is clean. The monthly check of a boiler is Test all stand-by
pumps and second is to Check all boiler mountings for damage or leaks and repair &
replace if necessary. Incorrect feed water treatment is commonly causing hard

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 deposits or corrosion. Insufficient blow-down will cause sludge deposits in the tubes
and accumulation of sludge in the bottom of the boiler. If hard deposits are not
removed.it may lead to overheating in the boiler plate material, which is exposed to
the flame in the furnace wall area. This may cause material damages. Incorrect feed
water- treatment does not always lead to hard deposits. For example, a too low or too
high pH-value may give an electrolytic reaction causing corrosion in the boiler. When
the boiler interior is inspected, examine all parts carefully and be attentive to deposits,
corrosion, and cracks. It is advisable to pay special attention to this inspection. IN
Procedure and remarks for Boiler inspection first is to Shut off the boiler and allow it
to cool (below 100 deg C). Note that the boiler should NOT be depressurized by
lifting the safety valves and then filled with cold feed water as the stress induced by
too rapid cooling may cause damage. Second is to Empty the boiler and close all
valves. If the boiler is connected to a second boiler, check that the valves between
them are closed. Third is to Unscrew and remove the manhole hatch(es) on the boiler
and enter the boiler when it is sufficiently cold. Check the welding in the boiler. A
careful examination should be carried out with respect to any possible corrosion or
crack formation. Special care should be taken to the water line area in the pressure
vessel where oxygen pitting may occur and if deposits are forming in the boiler tubes,
the boiler should be chemically cleaned it is advisable to consult a company of
cleaning specialists who will examine the boiler deposits and treat the boiler
accordingly. We should take note that after chemical treatment the boiler should be
blown down at Least twice a day for approximately one week. This will ensure that
excessive sludge deposits due to chemical treatment do not collect in the bottom of
the pressure vessel Contamination. If the boiler is contaminated with foreign
substances like oil, chemicals corrosion products etc., it is very important to act
immediately to avoid damage to the boiler. Fourth is to Check the function of the high
steam pressure switch by lowering the set point or by raising the steam pressure, e.g.
by closing the main steam valve slowly and the burner must stop automatically

IV. FORMATIVE ASSESSMENT:

I. Essay (25 pts)

Discuss inspection and safety checks on a boiler system (min. of 100 words). Write your
answer on the space below.

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____In inspecting the boiler, we should first conduct Inspection of furnace. The furnace
should be inspected at least twice or three times a year. During this inspection, the following
issues should be taken into consideration: Check for cracks at the refractory and that the
furnace walls are free from excessive soot deposits. Carefully examine the area opposite the
burner. Too much soot deposits indicate that the burner should be adjusted. Check that the
smoke and stay tubes are intact and that soot deposits are within normal limits. Then we
should conduct inspection of exhaust gas section. The exhaust gas section should be
inspected at least twice a year. During this inspection, the following issues should be taken
into consideration: Check the welding in the exhaust section. A careful examination should
be carried out with respect to any possible corrosion or crack formation. Check that the inlet
box and outlet box are intact and that soot deposits are within normal limits. Check that the
smoke tubes and stay tubes are intact and that soot deposit are within normal limits. The
boiler water side must be carefully inspected at least twice a year. This inspection is of great
importance and no doubt the most important of all the maintenance measures. Since it has a
direct influence on the boiler longevity and on the security. At these inspections, hard
deposits, corrosion, and circulation disturbances can be found at an early stage, and
preventive measures must be taken to avoid unexpected material damage and boiler break
down. The presence of hard deposits at the furnace wall and the smoke tubes reduces their
heat transfer properties and decreases, the capacity of the boiler. Further, it can be established
whether the feed water treatment is satisfactory and whether the blow down is carried out
sufficiently. Layers of thin oil film are exposed to the heating surfaces cause a bad heat
transfer in the boiler, leading to overheating followed by burned out pressure parts, in order
to remove such contamination a boiling out or acid cleaning are performed immediately We
should always remember that corrosion products from the pipe system or insufficient boiler
water treatment may result in corrosion in the boiler itself. It is therefore important to observe
that such circumstances do not occur in the
system._____________________________________________________________________
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V. STUDENT REFLECTION
Write a min. of 300-word Reflective Learning Report. You may refer to the guide questions
below. Write legibly and submit your work at the end of week.

Guide questions:
1. Think about what you have done.
Share your thoughts in different perspective, what transpired during your activities and
evaluate your actions.

2. Think about what happened.

What you did and what didn’t work.

3. Analyse what happened.

Explain what your learnings are as well as your difficulties and make a plan on how you
would improve.

I think that the weekly routine of a boiler is to drain each water level glass for about

10-15 seconds. In case of contaminated boiler water or insufficient water treatment, the

draining of the water level glasses must be done more often. Check the safety water level

device. Depending on the boiler water tests blown-down the boiler. An internal boiler

inspection consists of all waterside areas of the vessel (steam, blow-off, and water

connections), and fireside conditions, as well as deaerators, superheaters, and economizers.

The safety arrangements in a marine boiler is that To ensure the fuel system is operating

efficiently, it is fitted with the following boiler safety features. Low fuel oil pressure alarm.

The fuel to the burner is provided using a fuel oil pump. Two pumps are installed (one kept

as standby) to ensure there is no operational hindrance in case of failure of one pump.

I understood that Mechanical damage is the most frequent incident that happens with

a boiler, second is the Boiler Fire And Meltdown Anything that is hot and involves burning

of fuel poses a high risk of fire hazard, Third is the Carbon Monoxide Toxicity followed by

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Scalding Incidents & Hot Burns and lastly is the Boiler Explosion. An internal boiler

inspection consists of all waterside areas of the vessel (steam, blow-off, and water

connections), and fireside conditions, as well as deaerators, superheaters, and economizers.

While evidence of internal corrosion and scale, leaks, overheating, and flame impingement

are noted and documented in the boiler inspector's report, the root cause may require

additional resources. Both the owner/operator and the water treatment consultant are this

resource, playing an active role at this inspection, and in any subsequent adjustments made

tot he boiler management program. Boilers are typically subject to routine inspections

annually, although more frequent inspections may be necessary if performance malfunctions

are identified, for older systems, or in certain areas based on state or local regulations.

Regular inspections are imperative for minimizing downtime due to unexpected malfunctions

and ensuring that boilers are in good working order.

I learned that the boiler inspector looks for all internal walls and surfaces are

inspected, looking for any signs of leaks, corrosion, overheating, or other structural issues

within the boiler. Waterside areas. All waterside areas of the boiler are inspected, including

blow-off, water connections, and steam areas. Marine boiler is oil-fired, high-pressure device

with its own firefighting apparatus. The crew on board should be aware of application

method of local fire extinguisher (foam type). In addition, fire drill needs to be carried out

periodically to prevent accidents. attention in boiler operation. Keeping your boiler properly

maintained can help prevent a host of potential issues that make it work harder and erode its

energy efficiency, such as leaks, sediment build up in the tank, dirty burners, and corrosion.

Typically, a steam boiler should receive servicing at least once per year. Any kind of safety

failure with a boiler can have serious consequences, and so a yearly inspection will help to

spot any safety issues that need to be addressed.

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