Since the steam boiler operates under high pressure and temperature, safety cannot be ensured only by intervening in case of malfunction. Daily operating controls, planned maintenance and periodic control in accordance with the legislation are three separate processes that complement each other.
Maintenance aims to keep equipment in working order. Periodic control means that the authorized person evaluates and reports the safe use conditions of the equipment through inspection, measurement and tests. Maintenance does not replace periodic control, and the periodic control report does not replace daily operator controls.
Responsibility in terms of legislation
The employer is obliged to ensure that the equipment used is suitable for the job and safe for employees. The control of equipment subject to periodic control must be carried out by authorized persons defined in the current legislation and by following the necessary contract/reporting processes. Due to the changes published at the end of 2025, one should not act with the procedural information in old internet articles; Current Ministry of Labor and Social Security statements should be checked.
Control period; It is determined by considering the current regulation, relevant standard, manufacturer’s instructions, equipment condition and risk assessment together. Additional inspection may be required after major repairs, relocation, accident, long-term downtime or change affecting safety.
Daily operator checks
At least the following points should be observed at the beginning of the shift:
- Readability and consistency of water level indicators,
- Operating pressure and temperatures,
- Operating status of feed water pumps,
- Burner flame, ignition and fuel pressure,
- Steam, water, fuel and flue gas leaks,
- Unusual noise, vibration or smell,
- The condition of the blowdown and condensate system,
- Alarm and fault records,
- Boiler room ventilation and layout.
Keeping a signed shift form for these checks makes it easier to notice slowly developing problems. The situation outside the normal value should not just be reset and passed; The cause should be investigated.
Weekly and monthly maintenance titles
Maintenance interval should be determined according to the manufacturer’s manual and operating intensity. In general:
- Function testing of water level control devices,
- Low water level safety chain,
- Burner flame monitoring and fuel cut-off device,
- Pump, motor, coupling and bearings,
- Leakage in valves and armatures,
- Sealing of chimneys and smoke channels,
- Water analysis, chemical dosage and blowdown adjustment,
- Condensate return temperature and pollution risk,
- Insulation and hot surface protection,
- Automation sensors and alarm history
It should be checked in a planned manner.
What is done for annual posture maintenance?
After the boiler is stopped safely and made depressurized, cold and isolated, the internal and external surfaces are examined. The cover should not be opened or the equipment should not be worked on without following the locking and tagging procedure.
Water side
Lime, mud, corrosion, pitting and leakage traces are looked for. Merely removing the residue is not enough; The reason why it occurs should be investigated in terms of water analysis, condensate pollution, chemical dosage and blowdown.
Smoke side
Soot, ash and combustion residues reduce heat transfer. Ash burner, smoke pipes, turbulators, refractories and cover seals are checked. Local color changes may be a sign of overheating.
Burner and fuel system
Ignition electrodes, flame detector, filters, pumps, gas valves, pressure switches and air dampers are checked according to the manufacturer’s instructions. Combustion adjustment should be made with the appropriate flue gas analyzer, not by eye decision.
Safety and measuring elements
Safety valves, manometers, pressure limiters, water level indicators and low water protection are tested with appropriate methods. Calibration and adjustment records are stored.
Is hydrostatic testing alone sufficient?
No. Hydrostatic testing is part of the evaluation of the tightness and strength of the pressure body under certain conditions. Visual inspection, wall thickness measurement, welding and surface inspections should be handled together with functional control of safety equipment and document review.
Test pressure should not be determined by a fixed multiplier taken from the internet. The boiler’s label, design standard, manufacturing documents, operating pressure and current legislation should be evaluated by an authorized control expert.
Documents to be prepared before the control
- Boiler label and serial number,
- Manufacturing/technical file and conformity documents,
- Use and maintenance manual,
- Previous periodic control reports,
- Maintenance and repair records,
- Safety valve and measuring device documents,
- Water analysis and chemical monitoring records,
- Fault, alarm and important change records,
- Authorized personnel and operating instructions.
The document and the equipment information on the field must match. If the boiler plate cannot be read or the settings of the safety elements are unclear, the issue must be resolved before the inspection.
The effect of maintenance on efficiency
Soot and scale make heat transfer difficult, requiring more fuel for the same steam production. Incorrect air-fuel ratio increases stack loss; Leaks and faulty traps waste the steam produced. Therefore, maintenance is not only a security expense but also part of energy management.
Maintenance plan for steam boiler and auxiliary equipment should be prepared according to device type, fuel and working hours. If extensive changes are required to existing facilities, industrial facility revisions should be addressed with an engineering evaluation.
Frequently asked questions
Is boiler maintenance the same as periodic control?
No. Maintenance maintains operating reliability; Periodic control is the inspection, testing and reporting activity of the authorized person within the scope of the legislation.
Can periodic checks be made while the boiler is running?
Some business observations can be made; The boiler must be stopped and prepared safely for operations such as internal inspection or pressure testing. The authorized person determines the method.
Should the safety valve be tested manually?
It should not be intervened randomly without the manufacturer’s instructions and authorized procedure. Incorrect testing may pose a risk of hot fluid release and equipment damage.
Can the boiler be used if the control report is inappropriate?
The classification of the report and the evaluation of the authorized person are taken as basis. The equipment should not be operated until the nonconformity affecting safety is eliminated.
Technical resources
- T.R. Ministry of Labor and Social Security, Regulation on Health and Safety Conditions in the Use of Work Equipment and its amendment of 23 December 2025.
- İSGÜM Cylindrical Boiler Periodic Inspection Guide.