Inspection of Boiler: Importance, Process, and Safety Measures

Inspection of Boiler: Importance, Process, and Safety Measures

Boilers are critical equipment in power plants, industrial facilities, and manufacturing units, generating high‑pressure steam at elevated temperatures. Any abnormality in a boiler can lead to severe accidents, causing heavy losses to both personnel and machinery. To ensure safety, efficiency, and reliability, regular inspection of boilers is mandatory.  

🔹 Why Boiler Inspection is Important

- Prevents accidents and equipment failures  

- Ensures compliance with safety regulations  

- Detects corrosion, erosion, and cracks at an early stage  

- Improves boiler efficiency and lifespan  

- Reduces maintenance costs by identifying problems before they escalate  

🔹 Areas to Inspect During Boiler Shutdown

During scheduled shutdowns, the following components are thoroughly inspected:  

- Water Wall – Checked for corrosion, swelling, and warping.  

- Superheater – Inspected for blistering, burning, and cracking due to high temperature.  

- Economiser – Examined for erosion and corrosion caused by flue gases.  

- Air Heater – Checked for deposits and wear.  

-  Tubes are cleaned and inspected to detect corrosion, erosion, swelling, warping, blistering, burning, and cracking.  

🔹 Internal Inspection of Boiler

Internal inspection focuses on the waterside of pressure parts:  

- Water Header – Hand hole caps are opened to check for corrosion and pitting.  

- Steam Drum – Manhole is opened after draining water and isolating connected pipeline valves (feedwater, dosing, blowdown, drain, and sampling lines).  

- Drum Internals – Cleaned thoroughly and inspected for corrosion and pitting.  

🔹 Cleaning Before Inspection

Proper cleaning is essential before inspection:  

- Scaffolding is arranged to access the furnace and bank tubes.  

- Tubes are cleaned using:  

  - Water  

  - Jute or sack  

  - Brushes  

  - High‑pressure hydro jet for stubborn deposits  

🔹 Annual Boiler Inspection

All these activities are part of the annual inspection of boilers, which is a detailed process ensuring that the equipment remains safe, efficient, and compliant with industrial standards. A separate blog post is provided for step‑by‑step guide to annual inspection procedures.  

📌 Key Takeaways

- Boiler inspection is vital for safety and efficiency.  

- Both external and internal inspections are necessary.  

- Cleaning methods like hydro jetting improve inspection accuracy.  

- Annual inspections are mandatory for long‑term reliability.