Complete daily maintenance operations for steam boilers (Simple and practical, directly executable by teams)

I. Check before starting each shift (Mandatory)
Water level inspection
Check that the water level in the water level gauge is within the normal range (1/2 to 2/3), and there is no shortage or full water.
Regularly flush the water level gauge to prevent blockage and false water level.

Pressure and Instruments
The pressure gauge indicates normally and the pointer is not stuck. The pressure gauge is within the validity period of verification.
The safety valve is in good condition, without jamming or leakage, and the lead seal is intact.

Water Supply and Water Quality
Check if the water softener is operating normally and if the water level in the water tank is sufficient.
Raw water must not be directly fed into the furnace to prevent scaling, bulging and pipe burst.

Combustion and pipelines
There is no leakage in the gas/fuel pipeline and the valve opening and closing status is correct.
The fan, water pump and circulating pump have no abnormal noise, no vibration and the oil level is normal.
The flue and damper are unobstructed and well-sealed.

Electrical automatic control
The indicator lights on the control cabinet are normal, the alarm system, ultra-low water level and overpressure protection are in good condition.
The emergency stop button and interlock protection are sensitive and effective.

Ii. Daily Inspection during Operation (once every 1 to 2 hours)
Stable control: Steam pressure, temperature and water level should be kept stable. Overpressure and overloading operation are strictly prohibited.
Regular blowdown (blowdown at the bottom of the boiler) : 1 to 2 times per shift, quick blowdown in a short time to remove sludge and sediment.
When discharging sewage, observe the water level. Discharging sewage at a low water level is strictly prohibited.
Furnace body appearance: No bulges, leakage, weld leakage or flange leakage.
Flue gas indicators: The color of the exhaust gas is normal, with no black or yellow smoke emitted. The burner is operating normally.
Equipment temperature: The temperatures of the bearings, motors and pump bodies are normal, and there is no overheating or scalding to the touch.

Iii. Maintenance after each shift’s shutdown
Close the fuel valve, shut down the burner, fan and water pump, cut off the power and hang a sign.
Cleaning: Carbon deposits and dust in the furnace and burner; Clean the dust collector and filter screen.
Inspection: Check for any leakage in manholes, handholes, flanges and valves.
Record: Fill in the operation log (pressure, water level, material consumption, sewage discharge, faults).

Iv. Daily Maintenance
Clean the conduits of the water level gauge and pressure gauge to ensure they are unobstructed.
Check all valves: they should operate smoothly without any internal or external leakage.
Check the liquid levels of water treatment chemicals, resins and salt tanks, and replenish salt and chemicals in a timely manner.
Wipe the boiler body and control cabinet to keep the machine room clean and well-ventilated.

V. Weekly maintenance
Manual tests: Manual safety valve tripping test, high and low water level alarm, overpressure interlock test.
Check the ash accumulation in the flue, chimney, economizer and air preheater. Clean the ash if necessary.
Lubrication: Apply grease to the bearings of the fan and water pump, and check the tightness of the belt.
Comprehensive leak detection: Soapy water leak detection for gas pipelines to eliminate leakage hazards.

Vi. Monthly maintenance
Internal inspection: Open the handhole to simply check the scaling and corrosion conditions of the drum and the heating surface.
Cleaning: Dust removal from the surface of the economizer and condenser, and descaling of the heat exchanger.
Calibration: Water quality testing (hardness, alkalinity, PH), if not up to standard, adjust water treatment promptly.
Tightening: All pipe flanges, anchor bolts and flue bolts are fully tightened.

Vii. Long-term Shutdown Maintenance (Key Anti-corrosion)
Short-term shutdown of the furnace (within 7 days) : Full water maintenance, maintain water level and slight pressure, and isolate from air.
Long-term shutdown of the furnace
Dry maintenance: Place desiccants inside the drying furnace and close the manhole valve.
Wet maintenance: Add corrosion inhibitors, fill with water and seal, and regularly test water quality.

Viii. Daily Prohibitions (Life-saving Clause)
It is strictly prohibited to operate with water shortage, full water, overpressure or overload.
It is strictly prohibited to disassemble the safety valve or block the interlock protection during operation.
It is strictly prohibited to carry out maintenance or tighten bolts under pressure.
It is strictly prohibited to leave scale untreated or to fail to discharge pollutants for a long time.
Unlicensed personnel are strictly prohibited from operating the boiler.

Ix. Simple Mnemonic Rhymes (Easy for Teams to Remember
Before starting work, check the water level and pressure gauge to ensure they are correct.
Frequent drainage during operation ensures that the water quality is not compromised.
After work, clear the accumulated dust and check for leaks or shortages in the valves.
Test the safety valve weekly and check for scale and mold prevention monthly.
When shutting down the furnace, it should be divided into dry and wet conditions. Safety comes first.