Measuring liquid levels inside boiler and pressure vessels is vital to safe operations. When a sight glass isn´t readable, that sight glass cannot show proper level inside of equipment and therefore become an unsafe instrument for measuring liquid level. With the growing popularity of other liquid level indicators such as level alarms, level transmitters, the sight glass is relegated to back-up status and is no longer the primary liquid level indicator. This creates an extremely hazardous situation with regards to actual liquid level in a boiler or vessel.
Years ago, when train locomotives operated on steam, the sight glass was the primary instrument for liquid level in the boiler. Those early versions of the sight glass were prone to problems and often failed. A sight glass failing inside the cab of a locomotive almost always meant serious injury to the engineer. As a result of those failures, sight glasses were improved time and again, until we have the modern sight glass of today.
With the introduction of level alarms, level transmitters and centralized control systems, the sight glass in the field is less utilized. The natural result of under-utilization leads to less dependence on the sight glass as a liquid level indicator. A sight glass that is not used or maintained naturally receives little or no maintenance. In fact, many sight glasses today are only maintained if they leak. Often times, the actual level cannot be seen in the sight glass. Unfortunately, this scenario has led to the deadly sight glass.
If transmitters fail, and or liquid level alarms fail, then the sight glass is the last device to display liquid level. If that sight glass cannot display the actual level, then it becomes a dangerous and useless instrument. When those other instruments fail, it is often too late to prevent catastrophe, because the sight glass is not ready to perform its function as a level indicator.
There are two solutions to this problem. The first is to replace every dirty sight glass with new one. This is an expensive solution. In fact, sight glass manufacturers recommend that dirty sight glasses be replaced. However, a more reasonable solution is cleaning dirty sight glasses. The cost of cleaning a sight glass is a small fraction of the cost of replacing a sight glass. This is a significant alternative to expensive sight glass replacement.
Maintenance of sight glasses is crucial to a safe working environment. Any good maintenance program must require these instruments be maintained properly. Without a maintenance schedule these instruments will naturally fail to perform their needed function. In addition, a scheduled period must be established to insure the functionality. This is the only way to take care of these needed instruments. To avoid unnecessary hazards, they must be cleaned and not replaced when they are merely dirty.
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