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High Pressure Boiler Inspection Audio (2)

Procedures (with Checklist)
Energy (6)
Last Updated: July 2, Posted by: Shelly Stazzone in Industry
2019 Resources Industry Resources

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A high-pressure boiler is defined as a boiler in which steam or vapor is generated at

Military (7)
a pressure equal to or greater than 15 psig, or a boiler in which water is heated at a
temperature of 250°F and a pressure greater than 160 psig, when water is heated Nameplates (6)
for use external to the boiler itself. High-pressure boilers include electric boilers,
miniature boilers, and high-temperature boilers for water and other liquids. Safety (18)

Standards (32)

Transportation (34)

Uncategorized (4)

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Boilers are typically subject to routine inspections annually, although more frequent RECENT POSTS
inspections may be necessary if performance malfunctions are identified, for older
systems, or in certain areas based on state or local regulations. Regular inspections ABYC Standards:
are imperative for minimizing downtime due to unexpected malfunctions and What Boat Builders
ensuring that boilers are in good working order.
Need to Know to

But what does a high-pressure boiler inspection involve? Here’s a look at the key Stay Compliant
steps in conducting an inspection on a high-pressure boiler. Download our high-
What is NSF/ANSI
pressure boiler inspection checklist for an interactive guide you can follow step-by-
step, or continue reading for information on: 51-2017?

5 PMMI Certification
• Pre-Inspection Preparation

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• Required Equipment for High-Pressure Boiler Inspections Training and Cost

• Safety Precautions for High-Pressure Boiler Inspections
Resources
• Scope of High-Pressure Boiler Inspections

Pre-Inspection Preparation
REQUEST A

The boiler’s user or owner is responsible for preparing a boiler for inspection, as well QUOTE
as preparing and performing a hydrostatic or pressure test when necessary. The
GET FREE
inspector should notify the owner or user of the date of inspection at least seven
days in advance, or according to the notice requirements outlined in applicable state SAMPLES
or local regulations.

Pressure boilers are covered under Section VIII of the ASME (American Society of ARCHIVES
Mechanical Engineers) “Boiler and Pressure Vessel Code.” State and local
August 2019
regulations may also apply, so owners and users of high-pressure vessels should
familiarize themselves with all applicable standards and regulations. Additionally, July 2019

inspectors should assess high-pressure boilers against all applicable regulations and June 2019
standards, so the specific inspection steps may vary between locations subject to
May 2019
different regulatory guidelines.
April 2019

To prepare a boiler for inspection, the user or owner should take the following steps, March 2019
as required by the inspector: February 2019

January 2019
• Drain water and wash the boiler thoroughly
• Remove man-hole and hand-hole plates, washout plugs, and inspection plugs in November 2018

water column connections October 2018

• Cool and clean furnace and combustion chambers
September 2018
• Remove grates from internally fired boilers
August 2018
• Remove brickwork insulation to determine the condition of the boiler, headers,
furnace, supports, and other parts July 2018
• Make preparations to provide proper access and control exposure to asbestos June 2018
fibers during inspection
May 2018
• Remove the pressure gage
April 2018
• Prevent steam or hot water leakage into the boiler by disconnecting the pipe or
valve at a convenient point, or through any other means approved by the March 2018
inspector February 2018
• Close, tag, and padlock non-return and steam stop valves before opening the
January 2018
manhole or hand-hole covers
• Open drain valves and/or cocks between the two valves December 2017

• Close, tag, and padlock blow-off valves after draining the boiler November 2017
• Disconnect blow-off lines between pressure parts and valves when possible
October 2017
• Open all drains and vent lines
September 2017

Hydrostatic pressure tests should not exceed 1.5 times the maximum allowable August 2017
working pressure, or other limits as defined by applicable state or local regulations. July 2017
The test should be controlled to ensure that the required test pressure is never
June 2017
exceeded by two percent (2%) or more. The water used to perform a hydrostatic test

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should be at least 70 degrees Fahrenheit but no more than 120 degrees Fahrenheit. October 2016
When hydrostatic tests are used to determine tightness, the pressure should equal
June 2016
the normal operating pressure but not exceed the release pressure of the safety
May 2016
valve with the lowest release setting.
March 2016
The boiler manufacturer’s cool down procedure should always be followed when February 2016
preparing a boiler for inspection. After cool-down, the boiler should be rinsed to
September 2015
avoid sludge deposits that can create problems later. If a cooled-down boiler will be
filled with water for an extended period, the appropriate wet lay-up precautions August 2015

should be taken to avoid corrosion. February 2015

January 2015
Required Equipment for High-Pressure October 2014

Boiler Inspections September 2014

August 2014

March 2012

Anything small enough to fall down a tube should be removed prior to entering a
boiler. That includes watches, earrings, rings, and other items. Recommended
equipment for performing high-pressure boiler inspections includes:

• A safety hat and safety glasses

• Safety shoes
• Gloves
• Coveralls
• Flashlight
• Camera (with a securely-closed battery compartment)
• Inspection mirror
• Magnet
• Containers for storing deposits
• A knife, screwdriver, or other scraping device
• Any necessary atmospheric testing equipment
• Any additional advanced testing equipment required

Safety Precautions for High-Pressure Boiler

Inspections

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In addition to having the appropriate safety gear mentioned above, inspectors (as
well as owners and users preparing boilers for inspection) should follow all plant
safety procedures. Other safety recommendations include:

• Inspect with a partner or have an inspection attendant

• Request that other boilers are not blown during the inspection
• Ensure that all valves are turned off and locked out prior to inspection, including
fuel, blowdown, steam, chemical feed, and feedwater valves
• Check the temperature of the bare metal to ensure that the boiler is not too hot
• Ensure that the conditions are not hazardous by using atmospheric monitoring
equipment

Scope of High-Pressure Boiler Inspections

Inspectors should always review past inspection reports and any design documents
available for the high-pressure boiler prior to initiating an inspection. An inspection
includes a thorough examination and analysis of both waterside and fireside
surfaces, and inspections may also include economizers, feedwater heaters,
deaerators, and other related equipment.

Inspectors look for evidence of corrosion, leaks and cracks, deposits and plugging,
and any other damage, taking photos of all damage and potential concerns and also
discussing all concerns in the written report. Inspectors also verify the functional
efficacy of operational and safety controls.

Download our interactive checklist for a step-by-step guide to high-pressure boiler

inspection procedures.

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