Annual Insurance Inspection Preparation for Babcock Steambloc Boiler

As part of an annual insurance inspection preparation for a Babcock Steambloc Boiler at a paper mill in Cumbria, our team carried out a comprehensive service and inspection programme under strict time constraints. With limited downtime available, work began early on a Saturday morning to ensure the boiler was fully serviced, tested, and returned to operation by the following Friday afternoon.

The process began with the safe removal of key components, including:

• 6-inch steam valves
• Klinger sight glasses
• Hopkinson blowdown valves
• Feedwater valves
• Manlid and mudlids

Once these components were removed, the front doors of the boiler were carefully lifted using certified lifting equipment, and a full internal cleaning procedure was carried out. This included descaling and cleaning the furnace, smoketubes, and waterside areas to ensure maximum operational efficiency. Additionally, all flange faces were cleaned and prepared for the installation of new gaskets.

The removed steam valves, lids, and fittings were returned to our workshop for a detailed overhaul process, which included:

1. Full strip-down of each component to assess condition.
2. Cleaning and inspection of internal parts for signs of wear, erosion, or fatigue.
3. Re-assembly to manufacturer specifications.
4. Re-packing with graphite-based packing material for high-temperature sealing performance.
5. Hydraulic testing at 1.5 times working pressure to verify integrity and safety compliance.
6. Safety valve resetting to ensure correct operation and pressure protection.
7. Protective re-painting of components for corrosion resistance and longevity.

Following workshop refurbishment, all components were reinstalled and reassembled on-site. The boiler was re-commissioned and fully operational, meeting all insurance inspection requirements within the allocated timeframe.