Weekly Boiler Maintenance

Safety System Tests

• Test low-water cutoff (evaporation method): With the boiler operating, blow down the water column slowly until the burner cuts out. This confirms the primary safety device works. Record the cutoff level.
• Test secondary low-water cutoff: If fitted, test the independent low-water alarm using its test button or drain valve.
• Lift-test safety valve: If the valve has a try lever, gently lift it to verify the valve is not stuck. Steam should discharge and the valve should reseat cleanly.
• Test high-pressure limit: Adjust the high-pressure limit setpoint down to just above operating pressure. Verify the burner cuts out. Reset to the correct setpoint.
• Test flame scanner: Block the scanner view momentarily. The burner should shut down immediately (within 2 to 4 seconds).

Component Inspection

• Feed pumps: Check for leaks at seals, abnormal vibration, and temperature. Listen for cavitation noise. Verify standby pump starts when running pump is stopped.
• Water gauge glass: Blow down the gauge glass. Check for cracks, clouding, or leaks at fittings. Replace if damaged.
• Blowdown valves: Verify bottom blowdown valve seals completely after operation. No continuous dripping.
• Check linkages: Inspect burner air damper and fuel valve linkages for looseness or binding. Tighten or adjust as needed.
• Inspect stack: Visually check the stack for smoke, soot, or unusual emissions. Any visible smoke indicates a combustion problem.

Water Chemistry Review

1. Review the week's water test results. Look for trends in TDS, pH, and chemical residuals.
2. Check chemical consumption. A sudden increase may indicate a water quality problem or dosing system issue.
3. Verify the blowdown rate is appropriate for the TDS level. If TDS is consistently at the limit, increase blowdown or improve feedwater quality.
4. Send a water sample to the treatment company for a full analysis if any parameter is out of range.