Inspection, Maintenance, and Record Keeping
Inspection, Maintenance, and Record Keeping
This domain tests inspection types, maintenance planning, and records that prove the boiler was operated and maintained within code. The examiner expects you to know what an operator can inspect, what requires a qualified inspector, and what must be written down.
Inspection types
External inspections check the shell, fittings, gauge glass, safety valve, piping, insulation, and combustion air. Internal inspections require shutdown, cooling, isolation, and entry procedures; they look for scale, corrosion, cracks, tube leaks, and refractory damage. The National Board Inspection Code (NBIC) governs repairs and alterations; ASME stamps define original construction. A certificate of inspection must remain valid for operation.
Maintenance and records
Routine maintenance includes burner cleaning, flame scanner cleaning, linkage lubrication, water-level control checks, safety valve testing, and refractory inspection. Logs should show date, time, operator, water level, pressure/temperature, fuel used, blowdown, tests, and corrective action. Records support trends: rising stack temperature, falling efficiency, or repeated low-water trips.
Worked example
An operator finds the gauge glass shows a normal level but the try cocks show low water. The correct response is to shut down the burner, isolate the glass, and clean or repair the clogged lower connection. The reasoning: a false glass level is more dangerous than a low reading because it can hide a low-water condition; try cocks are an independent check.
Traps
Do not sign a log before the reading is taken. Do not record a safety-valve test without the valve lifting. Do not paint over valve data or cover inspection openings. Do not treat a repair as routine maintenance if it changes pressure parts.