Block 3 The Boiler House

Testing Requirements in the Boiler House Module 3.20

Module 3.20
Testing Requirements in
the Boiler House

The Steam and Condensate Loop

3.20.1

Block 3 The Boiler House

Testing Requirements in the Boiler House Module 3.20

Testing Requirements in the Boiler House

The following test routines are required by the UK HSE (Health and Safety Executive) for a
manned boiler house.

External chambers (float or probe type controls)

o

Daily:
1. Blow through of the chambers is required, using the sequencing purge valves to remove
any accumulated sludge.
2. Separately, the first and second low alarms are tested.

Weekly:
1. Lower the actual boiler water level to the 1st low (by evaporation), and then blow down to
the 2nd low.
The main reason for this weekly test is to ensure that the alarm is given, and at the correct
level, when the level drops slowly in the boiler (because floats could stick).
2. A high alarm is usually tested weekly.
Position 1 - Normal working
Gauge glass connection
Handwheel

Boiler connection

Drain
Position 2 - Blow through water
Handwheel

Drain
Position 3 - Blow through chamber
Handwheel

Drain
Fig. 3.20.1 Operation of sequencing valves

3.20.2

The Steam and Condensate Loop

Block 3 The Boiler House

Testing Requirements in the Boiler House Module 3.20

Direct mounted level controls with internal protection tubes

A daily test is still required, but this means dropping the actual level, unless test facilities are
incorporated. The time involved and the loss of heat, water and treatment chemicals means that
this is only really practical in smaller boilers.
The UK regulations for supervision state that, for standard (for example, non-self-monitoring,
high integrity) controls there must be a trained boiler attendant on site at all times that the boiler
is operating.

Testing requirements in the unmanned boiler house

In many countries and in all types of industries, there is a need or desire to run steam boiler plant
unattended. This has led to the development of special, high integrity self-monitoring level
alarms, and controls for increased safety in the event of low water conditions.
For externally mounted float controls, automatic sequencing valves are required, plus a control
system which will then carry out automatic sequenced blowdown of the external chambers and
electrical testing of the externally mounted boiler level controls (Figure 3.20.2).

Control box

Chamber connection
Blowdown valve
Boiler connection
Fig. 3.20.2 Automatic sequencing valves and control systems
for externally mounted float type level controls

Direct mounted float type level controls must be fitted with a test device, plus a control system
which will then automatically and electrically test the direct mounted level controls (Figure 3.20.3).
Steam
Signal to start
feedwater pump

Level controls

Level control box

Flue

Burner

Solenoid valve

Non-return valve

Fig. 3.20.3 Direct mounted float controls in a shell boiler

The Steam and Condensate Loop

3.20.3

Block 3 The Boiler House

Testing Requirements in the Boiler House Module 3.20

Automatic test system for direct mounted

float type level controls

Removable
probe head

With probe type, high integrity, self-monitoring

level controls, the self-checking facility is carried
out via the probe and its associated controller,
so a further, special control system is not required.

Probe body

The latest conductivity systems which incorporate

a high integrity self-monitoring feature, will check
for faults continuously, and electronically.
Faults can include the build-up of scale or dirt
on the probe and also any moisture leakage into
the probe. If such a fault is detected, the control
system will initiate an alarm and cause the boiler
to safely shut down.

PTFE insualtion

Comparator tip
Probe connection

PTFE insualtion

The main user advantage of these special low

water level alarms is not only increased safety
but also that daily testing is not necessary. This
means that there is little point in fitting high
integrity probe controls in external chambers,
where it would still be necessary to blow
through the chambers, on a daily basis, to
remove any sludge.

Level sensing tip

Probe type, high integrity, self-monitoring low

water level alarms are therefore fitted in internal
protection tubes.

Fig. 3.20.4 Typical high integrity

self-monitoring conductivity probe

The manual weekly test must still be carried out under UK regulations. In Germany, where
approved probe -type high integrity self-monitoring low water alarms are fitted, the interval
between manual tests is 6 months.
Under the UK regulations, if high integrity self-monitoring systems are fitted, supervision
requirements are reduced to the need to have someone available to respond to any alarm and
call for further assistance. An adequately trained security guard or porter could be considered
suitable.
Self-monitoring probes

Capacitance probe for level control

High alarm

Protection tubes

Control panel

Modulating control band

Gauge glasses

1st low 2nd low

Feedwater
Feedwater valve
Fig. 3.20.5 High integrity, self-monitoring, modulating control system

3.20.4

The Steam and Condensate Loop

Block 3 The Boiler House

Testing Requirements in the Boiler House Module 3.20

Summary
When the low water level alarm systems are housed in external chambers they will require
manually blowing down and testing, and this must be carried out at least once per day. In these
cases a trained boiler attendant must be on site whenever the boiler is operating including during
silent hours (nights and weekends).
The trained boiler attendant need not be permanently situated in the boiler house but must be
able to respond immediately to the level alarms.
When high integrity self-monitoring low level alarms are mounted in the boiler shell, since they
are automatically self-testing, they only require a full operational test by a trained boiler attendant
once per week.
When standard low level alarms (floats or probes) are fitted in external chambers, automatic
sequencing valves have to be fitted in order for the alarm system to be deemed self-monitoring.
A trained boiler attendant need not be on site at all times and another person (watchman or
porter) can be put in charge of the boiler instead, as part of his duties during the silent hours.
This person should always be ready to respond correctly to the boiler alarms, shutting down the
boiler if necessary. Thus, depending on the type of installation there are two possible types of
supervision: A trained boiler attendant (or technician), who must be fully conversant with the
operation of the boiler and its controls; or an individual such as a watchman who, although not
a fully trained boiler attendant, must be familiar with the alarm protocol and know the procedure
for shutting down the boiler.
Table 3.20.1 Testing required by UK HSE (Health and Safety Executive)
Standard controls
In external chambers
In shell

Daily test (plus true test weekly)

Daily (true) test

High integrity,
self-monitoring controls
Weekly (true) test

Testing steam boiler control systems

Any boiler regulations will emphasise that regular testing of any boiler control system, particularly
with respect to the water level, is an important requirement. All testing should be carried out
with the water in the visible region of the water level gauge.
All testing should be carried out by a trained boiler attendant. In the case of level devices mounted
in chambers with manual sequencing valves, testing involves operating the sequencing valves at
least once per day to lower the water in each chamber and to test the operation of the water
level control, and the controls / alarms at first and second low levels. Similarly for traditional
(non- self-monitoring) low water level alarms mounted directly in the boiler, the trained boiler
attendant must lower the actual boiler water level every day in order to test these alarms.
However, for high integrity self-monitoring controls mounted directly in the boiler, there is no
need for daily testing.
For all types of level control system there is a weekly test to be carried out, and this involves
isolating the feedwater supply, lowering the water by evaporation to first low level and blowing
down to second low level. This weekly test is a full functional test of the systems ability to cope
with actual boiler water level change.
It is recommended that all tests be properly logged in a boiler house log book, for which the
Engineering Manager is responsible.

Footnote: These basic notes are based on UK boiler house practice, rules, and regulations.
These regulations vary around the world, some examples follow:
Australia
Canada
Italy

Dynamic (float type) low water alarm systems are currently called for by boiler regulations.
A boiler plant engineer must always be present during boiler operation.
Boiler regulations state that the second low water alarm has to be of a mechanical type.

The Steam and Condensate Loop

3.20.5

Block 3 The Boiler House

Testing Requirements in the Boiler House Module 3.20

Questions
1. Which weekly tests of level controls should be conducted on a boiler with
external level chambers?
a| Evaporate to 1st low and then blowdown to 2nd low

b| Evaporate to 2nd low

c| Blowdown to 1st and 2nd low

d| Weekly tests are not necessary

2.

By which means are level controls in external level chambers tested?

a| Hydraulic test

b| Electromagnetic test

c| Draining the chambers through an isolation valve

d| By a sequencing purge valve

3.

Which tests are required on high integrity self-monitoring direct mounted level
controls?

a| None

b| Daily functional test by evaporating to 1st low and then blowing down to 2nd low

c| Weekly conductivity functional test

d| Weekly functional test by evaporating to 1st low and then blowing down to 2nd low

4. Why would high integrity self-monitoring low-level controls not normally be

used in external level chambers?
a| They are only suitable for direct mounting in a boiler

b| Three chambers would be required, one for 1st alarm,

one for 2nd alarm and one for the level control

c| There would be no advantage because the chambers

would still need to be blown down daily

d| Cost; automatic sequencing purge valves would have to be fitted

5. Which of the following is a possible financial disadvantage of level controls fitted

in external chambers?
a| The sensed level is never the same as the level in the boiler

b| Water in the boiler must be lowered each day

c| The alarms must be tested weekly by evaporating to 1st low and

then blowing down to 2nd low

d| A trained boiler attendant must be on site whenever the boiler is in operation

6.

If boiler plant fitted with float level controls in external chambers is to be left unattended

a| The plant cannot be left unattended unless self-monitoring probe controls are fitted

b| There will be no need for daily lowering of the water in each chamber

c| Automatic sequenced blowdown of the chambers and

electrical tests facility must be fitted

d| In addition to c, a high integrity self-monitoring probe must be fitted in the boiler

Answers

1: a, 2: d, 3: d, 4: c, 5: d, 6: d

3.20.6

The Steam and Condensate Loop