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.
When other level instrument fails, the sight glass is the only instrument that can provide accurate level information to the operators. Often, when those other instruments fail, the operator will try to find the liquid level in the sight glass, only to discover that neglect has rendered that sight glass incapable of displaying level. At this point catastrophe is almost certain. There are simply no other instruments to provide accurate level instruments. An industrial accident is almost a certainty at this point.
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.
Sight glasses are absolutely vital to safe operations. Therefore, maintenance of sight glasses is also vital for plant safety. The best way to assure a sight glass is in good working condition at all times is to inspect them regularly and provide immediate maintenance when needed. Only when operations and maintenance personnel work together and share information can a good inspection program be backed up with proper maintenance. To avoid significant risks, sight glass cleaning is an appropriate and effective alternative to costly replacement.
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