Boiler Inspection Procedure
Prepared By
Engr. Md. Sharafat Ali
Inspector of Boilers
Office of the Chief Inspector of Boilers
Cell: 01711-736644
E-mail: bdsharafat@yahoo.com
Boiler Inspection for Registration
Drawing & Design verification
Tube plate, shell, fire drum, tube etc checked
Examine the manhole, mud-hole, hand-hole etc
Calibration pressure limit switch & pressure gauge
Examine safety valve and others valve
Boiler Inspection for Registration cont..
Test the gauge glass set
Check water feeding line, fuel supply line and steam line
Examine insulation and refractory material
Non-Destructive test (NDT) of welding joint
Hydraulic test of boiler
Steam test and adjust the safety valve
Drawing & Design verification:
Assemble drawing:
Heating surface calculation:
Boiler stamping:
Working pressure calculation (BBR):
(t - 2) x S x J
W. P .=
CxD
Here,
W. P. = the working pressure in lbs. per square inch;
t = the thickness of shell plates in inch;
S = the minimum tensile strength of the shell plates in tons per
square inch
J = the percentage of strength of the longitudinal strength
C = is a co-efficient
Boiler Inspection photograph
Boiler thoroughly Inspection Boiler shell ultrasonic test
Boiler Hydraulic test
Short term Initiative to increase boiler efficiency
Introduce flow gas analyzer
Maintain proper air fuel ratio
Must be installed feed water softening plant
Introduce automatic blow down system
Perfect insulation should be maintain
Boiler attendant and related personnel should be trained
properly
Long term Initiative to increase boiler efficiency
Stack economizers should be installed
Air preheater unit should be installed
All the condensate recovery potential should be utilize
Possible waste heat recovery techniques must be applied
Long term initiative for boiler safety
Must be installed two safety vale
Two water level indicator
Should be include two water pump
Safety valve should be set at the approved pressure
Automated low water alarm
Daily inspection and data record
Check the log book record for preventive action
verify the validity of boiler operation certificate
Check water level of feed tank and boiler
Check fuel supply line
Check steam supply line
Daily inspection and data record cont..
Blow down the bottom
Observe the water softener and regenerate the softener
Record water, fuel, steam temperature and pressure
Check the blow off of safety vale
Observe flame color, gauge glass, pressure gauge and stake
temperature
Weekly inspection
Low water level control and burner shutoff operation
Check the operation of the fuel supply valves
Maintenance the boiler burner
Observe the modulating control of pressure gauge
Check the indicating lights and alarm system
Weekly inspection cont..
Asses the motors for noise and vibration
Look for leaks fuel, water or flue gas
Check the high and low gas pressure switch
Test the gauge glass condition
Test the water parameter PH, TDS and Hardness
Monthly inspection
Check the burners diffuser for any deformation,
burning and cracking
Check the free movement of air damper devices
Check the boiler outside for signs any hot spots
Check fuel supply line for leakage and damages
Check pressure limit controls
Clean burner nozzle and ignition electrode
Monthly inspection cont..
Check adequate combustion air fuel supply
Check the stake leakages, damage or deterioration
Check the refractory for cracking and deterioration
Calibrate the all pressure gauges
Check the steam supply line.
Check water pump gaskets and non return valve
Annual inspection
Inspect and clean fire and water side of boiler
Thoroughly clean the tubes and tube plates
Descaling tube and tube plates
Check the safety valves, main stop valve, blow down
vale and ensure leak-proof to all
Replace all gaskets if necessary
Annual Inspection cont..
Check insulating and refractory material
Ensure all the electrical connections are tight
Examine and clean flame sensor and burner assembly
Replace boiler softener chemical
Hydraulic test of Boiler
Hydraulic test of Boiler :
A hydraulic test is a way in which boilers can be
tested for strength and leaks. The test involves filling the
vessel with a liquid usually water, which may be dyed to
aid in visual leak detection and pressurization of the
vessel to the specified test pressure.
According to Bangladesh Boiler Regulation every
boiler shall be hydraulically tested in the presence of an
Inspector or Inspecting officer. Pressure should be one
and half times the working pressure plus 50 lbs per
square inches.
Hydraulic test of boiler:
Boiler preparation for inspection of renewal certificate
Some condition according to BBR- 356:
Boiler shall be empty and thoroughly clean.
All doors of manholes, hand holes and sight holes, fire bridge, brick
arches, burner and mechanical stoker fittings shall be removed.
All valves, cocks and mountings shall be opened up and taken apart .
All smoke tubes, exterior of water tubes, smoke boxes and external
flues shall be swept clean.
Preparation for boiler inspection
Operator responsibilities for boiler safety
Maintain the normal operating water level.
Never add water to hot boiler when the water level cannot be
determined.
Tests safety valves regularly .
Follow SOP of own industry.
Maintain proper steam pressure and water temperature.
Routinely test the low water fuel cut-offs and feed water pump
control.
Operator responsibilities for boiler safety cont..
Routinely blow down the boiler water.
Test the gauge glass everyday.
Maintain the burner according to manufacturers recommendation.
Maintain proper fuel and oil temperature or gas pressure.
Record fuel consumption regularly.
Maintain optimum feed water temperature.
Any question or suggestion ?
Thank you
