SOP 138-47HV

OPERATION, PREVENTIVE MAINTENANCE, AND INSPECTION OF HIGH PRESSURE

BOILERS
VA Hudson Valley Health Care System
Issue Date: July 30, 2013
Update: July 30, 2016

1. PURPOSE: To ensure boilers are providing required service to the Health Care System.

2. POLICY: Engineering Service has implemented mechanisms to ensure that all high-
pressure boilers and associated equipment are operating safely and efficiently.

3. RESPONSIBILITIES:

a. The Chief, Engineering Service is responsible for ensuring the implementation of this
policy.

1) Is responsible for reporting any safety devices that malfunction to the Director of the
facility.

b. The Utility Systems Operations Supervisor is responsible for ensuring that:

1) All preventive maintenance is performed and properly documented.

2) All records include: shift, daily, monthly and annual calculations of boiler efficiency,
use of: fuel, water, electricity, minimum and maximum steam demand, total steam
production, ambient temperature, and degree days.

3) Is responsible for reporting any safety devices that malfunction to the Chief Engineer.

c. Utility Systems Operators are responsible for not leaving any high pressure (15 psig or
greater) boiler unattended at any time, nor should they be relieved by unqualified persons
even for short periods.

4. PROCEDURES:

a. Any unusual occurrences as a rupture or explosion of a boiler or pressure vessel, a

furnace explosion, extensive damage from overheating, or any other unusual condition
will be reported immediately to VA Headquarters. A thorough investigation of the cause
and extent of the damage will then be performed by the facility and a written report
submitted as soon as possible.

b. Preventive maintenance inspections will be performed by qualified personnel only.

The following inspection will be made:

1) Water Treatment: Samples will be taken and tested daily. Results are maintained in the
plant.
2) External Boiler Inspection: Inspections will be conducted annually by an outside
agency. Results are maintained in the plant.
3) Internal Boiler Inspection: Inspections will be conducted annually by an outside
agency. Results are maintained in the plant.
4) Safety Test: Before any Boiler is placed into service, all safety devices shall be
tested, i.e.: High Water and Low Water Alarms and Cut Off, Flame Failure Test, and
High Limit Cut Off. Results shall be recorded in Daily Log Book.
5) Inspections required by VHA Directive 2008-062 are included in Attachment "A."

c. Provide training of “safe steamin” course as per VHA Directive 2010-031for Boiler Plant
Operators, Supervisors, and Managers of the Boiler Plant.

5. REFERENCES:
DMS&S Supplement MP-3
VHA Directive 2008-062
VHA Directive 2010-031

6. RESCISSIONS:
SOP 138-47HV, Operation, Preventive Maintenance, and Inspection of High Pressure
Boilers, dated July 8, 2010.

//s//
JOHN CLIFFE
Chief, Engineering Service

Originator: 138/JD
Distribution: WEB

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 Attachment A: Required Inspections and Operational Tests

(a) Key to Frequency Abbreviations

1. H = Hourly.

2. D = Daily.

3. M = Once per month.

4. 6M = Once every 6 months.

5. Y = Once per year.

6. 6Y = Once every 6 years.

(b) Frequency Chart

ITEM FREQUENCY

1. High pressure boilers (above 15 psig): inspect furnace and

other internal surfaces, closures and accessories. Y

2. High pressure boilers (above 15 psig): inspect exterior of unit,

casing, supports, closures, accessories, valves, controls. Y

3. Deaerator: inspection and wet magnetic particle testing

of welds of pressure vessel interior. 6Y

4. Boiler fouling and combustion gas flow check. Y

5. Tube leak check. Y

NOTE: The items preceding (1. through 5.) must be accomplished by a Qualified
Professional Inspector. The following items (6. through oo.) must be accomplished by a
qualified individual as determined by the medical center’s management. Such a
determination must be carefully made for each item and each individual.

ITEM FREQUENCY

6. Low pressure boilers (15 psig and below): inspect interior

in addition, exterior, supports, closures, accessories, valves, and controls.Y

7. Deaerator: interior cleaning and visual inspection. Y

8. Adjust burner combustion settings and calibrate oxygen trim. 6M

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9. Check vibration of burner fans. 6M

10. Calibrate instrumentation, monitoring, and control systems. 6M

11. Calibrate pressure gages and thermometers. Y

12. Operational Testing of Boiler Safety Devices:

a. Low-water cutoff (slow drain) M

b. Low-water cutoff shunt switch M

c. Auxiliary low-water cutoff (slow drain) M

d. Auxiliary low-water cutoff shunt switch M

e. High-water alarm M

f. Low-water alarm M

g. High-steam pressure cutout (recycle) 6M

h. High-steam pressure cutout (non-recycle) 6M

i. Steam safety valves (raise boiler pressure until valve pops) 6M

j. Steam safety valves (accumulation test at high fire) Y

k. Flame scanner M

l. Check gas vent for leaks 6M

ITEM FREQUENCY

m. High-gas fuel pressure cutoff 6M

n. Low-gas fuel pressure cutoff 6M

o. Gas fuel safety shut off valves proof of closure 6M

p. Leak test gas fuel safety shut off valves 6M

q. High-fuel oil temperature cutoff (heated fuel) 6M

r. Low-fuel oil temperature cutoff (heated fuel) 6M

s. Low-atomizing pressure for fuel oil 6M

t. High-fuel oil pressure cutoff 6M

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 u. Low-fuel oil pressure cutoff 6M

v. Fuel oil safety shut off valves proof of closure 6M

w. Leak test fuel oil safety shut off valves 6M

x. Check operation of Liquid Petroleum Gas pilot 6M

y. Low-pilot gas pressure cutout 6M

z. Forced draft fan motor interlock 6M

aa. Forced draft fan damper wide open for purge 6M

bb. Boiler outlet damper wide open for purge 6M

cc. Purge air flow interlock 6M

dd. Timing for prepurge 6M

ee. Timing for post purge 6M

ff. Igniter timing 6M

ITEM FREQUENCY

gg. Low fire position interlock 6M

hh. Combustion air interlock 6M

ii. Main flame out; i.e., time to close valves 6M

jj. Ignition flame out; i.e., it is time to close valves 6M

kk. Minimum igniter flame test 6M

ll. Scanner not sensing ignition spark 6M

mm. Low-oxygen alarm and/or cutout 6M

nn. Prepurge setting of flue gas recirculation damper 6M

oo. Interlock of building outside air damper with burner control 6M

NOTE: The preceding safety devices are essential for ensuring the safest possible
operation. Any boilers not so equipped must be immediately programmed for retrofit, with

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priority given to providing two low water cutoffs per boiler and two fuel safety shut off valves
per fuel per boiler.

13. Boiler Plant Safety and Operational Duties

ITEM FREQUENCY

a. Overall plant operation H

b. Blowdown water columns D

c. Testing and adjusting water treatment D

d. Check furnace pressure 6M

e. Check combustion gas leaks into boiler room 6M

f. Clean waterside of boilers Y

ITEM FREQUENCY

g. Clean fireside and repair refractory Y

h. Operation of deaerator high and low water alarms M

i. Operation of deaerator steam pressure/temperature control M

j. Operation of condensate storage tank high and low water alarms M

k. Operation of all other alarm devices M

l. Operation of boiler economizers; temperatures in or out D

m. Review written procedures 6M

NOTE: The inspection and testing schedule is required for boilers in service during the
period. Boilers not in service must be inspected and tested prior to placing in service. For
boilers in service less than 3 months during the period, the schedule of inspections and
tests performed by qualified technicians for burner-related functions may be extended to
not exceed 1 year.