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.
Decades ago, the sight glasses used on boilers of steam locomotives were prone to failure. Often times, when that failure occurred inside the cabin of a locomotive, the engineers were seriously injured or worse. Sight glass manufacturers responded to these failures by redesigning the sight glass until it became safer. The result of those improvements leads us to the armored reflex sight glass of today.
However, as we´ve modernized and improved on the sight glass, we have also created high and low level alarms, in addition to level transmitters that relay a signal to a distant control computer. This naturally results in less importance being placed on the sight glass, simply because it is not typically the instrument used to indicate the level. As a result, many sight glasses do not receive any maintenance at all. And there are few programs in place to maintain those sight glasses. This lack of utility has led directly to sight glasses being a dangerous instrument without proper care.
When level transmitters do not operate correctly or in some way fail, the sight glass is then needed to find the correct level in pressure vessels. If that sight glass has not been maintained, its utility as a level indicator has failed. This places the working area at risk to accidents. By the time it is discovered to have failed, it is often too late to determine the correct level.
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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Leadership
Visibility
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