Suggested Maintenance Log Program
Summary: The following article is a part of National Board Classic Series.
The following maintenance items, as appropriate to the specific boiler system, need to be considered for implementation on a regular basis (e.g., daily, weekly, monthly, semiannually, annually). A checklist of the items should be incorporated into a maintenance log with provisions for checking off the item for the appropriate period. A separate log sheet is suggested for each period. The log sheets can be filed in a loose-leaf binder, and should be retained as a permanent maintenance record.
The log sheets can be used as a handy check-off system when establishing a facility maintenance program. In all cases the equipment manufacturer's recommendations should be followed.
DAILY
- Blow down and test low water cutoffs of steam boilers (once per shift for high pressure)
- Blow down gage glasses (steam)
- Blow down make up feeder (low pressure steam)
- Blow down boiler (steam)
- Check boiler contraol linkage
- Check boiler and system for leaks
- Check burner flame
WEEKLY
- Check compressor(s) lubricating oil level (control and atomizing)
- Check flame signal strength for both pilot and main flame, and record readings
- Check flame failure cutoff and timing
- Check pilot and main flame fuel shutoff valve closing
- Check ignitor and burner operation
- Check level in chemical treatment tank
MONTHLY
- Check compressor(s) air filter, and clean or replace as required
- Check boiler water treatment test results received from treatment company, adjust treatment as required
- Lubricate motor and equipment bearings
- Test fan and air pressure interlocks
- Check main burner fuel safety shutoff valves for leakage
- Check low fire start interlock
- Check high pressure/temperature interlocks
- Test low water cutoffs (hot water)
- For oil -- test pressure and temperature interlocks
- For gas -- test high and low gas pressure interlocks
- Manually lift safety/safety relief valves and check operation
SEMIANNUALLY
- Inspect burner components
- Check flame failure system components
- Check piping and wiring of all interlocks and shutoff valves
- Recalibrate all indicating and recording gages and instruments
- Perform a slow drain test for low water cutoffs (steam)
- Check combustion control system
- For oil -- check atomizers and strainers
- Test boiler safety/safety relief valves in accordance with ASME Boiler and Pressure Vessel Code, Sections VI and VII
ANNUALLY
- Perform the SEMIANNUAL maintenance procedures
- Check all equipment coils and diaphragms
- Perform a pilot turndown test
- Recondition or replace low water cutoff
- For gas -- check drip leg and gas strainer
- Clean boiler firesides
- Drain boiler, open manholes and hand holes, and clean watersides
- Have boiler inspected by a commissioned inspector
- Clean burner and gans
- Replace gaskets
- Leak-test all fuel valves
- Test operation of all controls and safety devices
- Have fuel-burning system adjusted using combustion test instruments
AFTER EACH PERIOD
- Make a record of all maintenance and parts replacement in the maintenance log
Editor's note: Some ASME Boiler and Pressure Vessel Code requirements may have changed because of advances in material technology and/or actual experience. The reader is cautioned to refer to the latest edition of the ASME Boiler and Pressure Vessel Code for current requirements.