Inspection, Maintenance, Testing and Record Keeping
Core concepts
Statutory inspection includes internal inspection, external inspection, hydraulic test, accumulation test and safety valve testing. Learn the roles of the inspector, competent person, boiler attendant and owner. Understand inspection intervals, certificates, log books, defect reporting and records of repairs.
Maintenance covers water level gauge maintenance, safety valve overhaul, burner servicing, tube cleaning, refractory repair, valve repacking, pump servicing and instrument calibration. Testing includes hydrostatic test pressure (usually 1.5 times MAWP for new boilers, but follow the applicable code), accumulation test and pop test.
Traps
- Confusing hydraulic test with accumulation test.
- Assuming a certificate lasts indefinitely; intervals depend on boiler type and jurisdiction.
- Failing to record defects; unrecorded defects are treated as unreported.
- Over-tightening safety valve settings during maintenance.
Worked rule of thumb
A hydraulic test is normally held at 1.5 × MAWP for new construction, and at the code-specified fraction for in-service boilers; never exceed the code value, and always record the test pressure, duration and result.