Keeping your Boiler and Level Instrumentation Operating Safely

Jun 1, 2023
3 min read

Updated: Aug 10

Check out our article in the Spring 2023 edition of Today's Boiler, the official magazine of the American Boiler Manufacturers Association (ABMA), written by our own Jim Kolbus, Senior Product Manager for Clark-Reliance LLC. Even in the heating season, it's an important time for good housekeeping and knowing where to find information. This article offers boiler operators and maintenance personnel helpful guidance on their water level indicators.

Boiler Room Housekeeping Checklist

Check your boiler room and the area surrounding the boiler for the following:

Items that may have been stored or left behind from repairs that are too close to the boiler, including tools, lubricants, and debris
Externally mounted piping and valves showing any signs of leaks - remedy the situation before it gets worse
Signs of missing insulation, which may have been temporarily removed for maintenance or inspection, and areas where additional insulation could improve safety for plant personnel
Heat tracing, if installed, is in working order - especially relevant for facilities that installed heat tracing after the severe winter freeze events in southern states in recent years
All level-indicating instruments are easy to read, with drain piping in good order and discharge directed safely away from the operator

Illumination Accessories Are Not Optional

It is vital to ensure all level indication instruments are in good working order with the illumination accessories attached, as needed. On transparent, flat glass or ported-type gages that require illumination for the operator to view water level, those illumination accessories must be kept in good working order. The best test for viewing the water level is to position yourself where you would normally read the instrument and confirm you can actually do so from that position.

Recognizing Wear on Tubular Glass

Tubular glass on low-pressure boiler applications is typically easy to read, but signs of wear to watch for include staining at the normal operating level, or a worn "white chalk" color that can hinder reading. If either symptom appears on any type of gage glass, it should be serviced promptly.

Cleaning and Testing Procedures

If a water gage glass appears contaminated, the first logical step is a blowdown of the gage - this flushes the gage in an effort to clean it internally. If successful, the gage can be returned to service. If not, the gage likely needs a rebuild or complete replacement.

Remote level indicator systems and low water level switches commonly include sensing components consisting of conductivity probes or floats. The testing method for these is also a blowdown. All plant procedures must be followed before conducting any testing or maintenance, and if more involved diagnostics are needed, consult the OEM for accurate information - most major manufacturers have detailed instruction manuals available on their websites.

Keep a Maintenance Log

Keeping a log to record maintenance on level gages helps track service life and minimize cost. It can also serve as an aid for planning future maintenance intervals on these instruments in your plant.

ASME Code References for Proper Care

For more helpful insight, see the proper care recommendations in the ASME Boiler and Pressure Vessel Code - specifically Section VI for heating boilers constructed to Section IV that operate up to 15 PSI and hot water supply boilers not exceeding 160°F, and Section VII for other power boilers. These documents include many details for startup, operations, and maintenance of boiler applications in a concise manner.

Any concerns regarding your boiler installation should be directed to your insurance carrier or local jurisdiction inspection authority.

Learn More

Visit ABMA.com to learn more about Today's Boiler, or contact Clark-Reliance directly for guidance on your specific level instrumentation maintenance needs.

Email: sales@clark-reliance.com Phone: +1 (440) 572-1500

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