Precautions for Operating Boiler Water Level Gauge

1. Routine Observation Requirements

1. Check the water level gauge every 15–30 minutes during boiler operation to confirm the actual water level. Never rely solely on remote level transmitters as the only reference.
2. The normal water level shall stay in the middle visible range of the gauge. If the level rises above high limit or drops below low limit, handle it immediately.
3. Observe the water surface fluctuation: slight regular fluctuation indicates normal circulation; static or violent surging water surface means abnormal boiler working conditions.

2. Standard Drainage / Flushing Operation Rules

1. Isolate the water level gauge from the boiler before overhauling or replacing glass plates/tubes by fully closing both steam cock and water cock.
2. Follow the correct flushing sequence (drain → steam → water) strictly, do not open three valves at the same time.
3. Slow down valve rotation speed during flushing; avoid sudden large opening to prevent rapid temperature shock cracking the glass.
4. Do not stand directly in front of the sight glass during draining and flushing to prevent scalding from splashing high-temperature steam and hot water.

3. Safety Protection Points

1. Check the anti-spill self-sealing ball inside the gauge cock regularly. If the glass bursts, the steel ball shall automatically block the passage to stop leakage. Replace failed cocks at once.
2. Keep the protective cover intact. Do not remove the anti-splash shield during operation.
3. No collision, knocking or heavy impact on the glass plate/tube to avoid breakage.
4. If the glass cracks and medium leaks, quickly close steam and water cocks to cut off the medium before maintenance.

4. Temperature & Pressure Operation Limits

1. Do not operate the boiler beyond the rated pressure and temperature of the supporting water level gauge.
2. Cold flushing on hot glass is forbidden; preheat slightly when the boiler restarts after shutdown to prevent thermal cracking.
3. If the boiler pressure rises sharply, reduce pressure slowly instead of quick draining through the level gauge.

5. Daily Inspection & Maintenance Notes

1. Check all sealing surfaces, valve stems and drain nozzles for steam or water leakage daily. Tighten loose gaskets or replace sealing parts in time.
2. Clean scale and sediment on the inner glass surface regularly. Scaling will blur the liquid-gas boundary and cause misjudgment of water level.
3. Ensure all cock handles rotate flexibly without jamming. Lubricate valve plugs with high-temperature resistant grease periodically.
4. Verify smooth exhaust and drainage of the drain cock; clogged ports will lead to false water level readings.

6. Special Working Condition Precautions

1. During boiler startup: slowly open steam and water cocks step by step to warm up the gauge evenly, avoid sudden temperature difference breaking glass.
2. During boiler shutdown: drain residual hot water inside the gauge to prevent limescale accumulation after cooling.
3. When water shortage accident occurs: strictly follow boiler operation specifications, never blindly add cold water through the level gauge drain port.
4. In cold seasons: drain all residual water after long-time shutdown to prevent glass cracking caused by frozen expanded water.

7. Prohibited Operations

• Forbid using the water level gauge drain port as a regular boiler blowdown channel.
• Forbid disassembling any parts of the level gauge while the boiler is under pressure.
• Forbid blocking the drain and vent ports of the gauge cocks.
• Forbid running the boiler with damaged, cracked or opaque sight glass.