Boilers used to generate steam can range in size from that coffee machine at your favourite café, to large power station boilers that generate super-heated steam to drive the turbines that produce electricity.
Back in the day, steam trains, ships and traction engines were commonplace. At the time the only means of propulsion was steam engine power, which was produced by boilers.
Boilers can be dangerous!
Under extreme pressure due to the rapid expansion of the stream, boilers can be very dangerous. When a boiler explodes, the results are catastrophic.
Just look at how excited the kettle gets as it comes to boiling and releases steam when you make your next cuppa.
As a result of the disastrous effects of exploding boilers on steam powered engines the Boiler, safety standards or ‘codes’ were developed in the early 1900’s. These were used to ensure boilers were manufactured, operated and inspected for safe operation.
Since the introduction of boiler codes, the frequency of explosions has reduced. Incidences have not entirely stopped however largely due to the failure to adhere to safe work guidelines in boiler codes and standards.
Boiler Inspection Life-cycle
The Inspection of boilers begin at manufacture and continue for the complete life cycle of the boiler.
In detail, the design of the boiler and its components, many of which are pressure vessels, the materials used and the manufacturing processes are defined in various codes and standards.
It is essential that competent independent Inspection is conducted throughout the life cycle to ensure the boiler is constructed and operated safely.
Boiler Inspection Statutory Requirements
Statutory requirements are in place nationally in Australia and internationally to ensure the safe operation of boilers and associated pressure vessels, and pressure pipe systems.
Therefore the plant owner, agents for the owners, the “Person Conducting a Business or Undertaking” (the ‘PCBU’ as defined by Safe Work) ’s, engineers, operators, the Inspection Bodies all have a duty of care and responsibilities to maintain compliance.
Very significant legal consequences are prescribed for a failure to comply, including very hefty fines and jail terms.
Annual Boiler Inspections
To comply with regulatory requirements Boilers are inspected every year.
The process of inspection is very extensive. External inspections are conducted while the boiler is live and operating looking for any unusual parameter, leaks, vibrations, corrosion, and so on.
Then the boiler needs to be decommissioned, key elements and components stripped and prepared for a dry inspection. When re-built the boiler operation and all safety devices are tested for operation, including
- flame out shut downs
- alarms for low water
- water treatments
- essential pressure reducing devices or safety valves are tested at maximum operating pressures.
Only when the boiler is deemed to be safe to operate is a certificate issued.
Boiler Inspection Costs
The costs of boiler inspection is directly relevant to the size and ‘horse power’ of the boiler and associated equipment.
A small package boiler may be a few hundred dollars to inspect, plus the service and any repairs costs. A power station boiler plant will be tens of thousands of dollars for the complete shut-down work scope.
At the end of the day a very small price to comply with regulatory requirements and operate the boiler safety.
Click here to contact our In Service Inspection team regarding your boiler inspection enquiry