Regulation requires a steam boiler to be operated by a certified boilerman. However, a boilerman's duties may not be properly understood.
A boilerman certificate is much like a driving licence. A driver is not a qualified motor mechanic who can repair a vehicle. Similarly, a boilerman operates a boiler — he is not a repair or service technician for the boiler.
Water Level
Over eighty percent of all boiler accidents are related to low boiler water. Therefore, taking good care of the boiler water will eliminate eighty percent of boiler problems.
A boilerman's first task on entering a boiler room is to inspect the level gauge of the boiler and feedwater tank. A common practice is to size the feedwater tank to cater for ten minutes of boiler firing at maximum continuous rating (MCR). Ten minutes is the time a boilerman may leave the boiler room.
Blowdown
The primary purpose of blowdown is removal of dirt, sediment, and scale. It is an essential part of every boilerman's duty. ASME has a recommended blowdown procedure that differentiates operation of quick- and slow-opening blowdown valves. This procedure is not well known outside the US and is seldom practised elsewhere.
Regular blowdown prevents scale build-up which reduces heat transfer efficiency and can lead to overheating of pressure vessel surfaces.
Chemical Dosing
Boiler water must be chemically treated to prevent scale and corrosion. The boilerman is responsible for checking the chemical dosing system and ensuring that chemicals are replenished as required. Water samples should be taken regularly and sent for analysis.
Daily Checks
A boilerman's typical daily checks include:
- Water level gauge — inspect and function-test
- Feedwater tank level
- Steam pressure gauge reading
- Safety valve condition (do not manually lift except during authorised tests)
- Blowdown — bottom and water column
- Burner and flame condition
- Chemical dosing levels
- Log entries for all readings