Steam Boiler Inspection
Need your Steam Boiler inspected in line with PSSR2000 regulations? Get a quote today to ensure you remain compliant.
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Steam Boiler Inspection
Need your Steam Boiler inspected in line with PSSR2000 regulations? Get a quote today to ensure you remain compliant.
Steam Boiler Thorough Examination
Steam Boilers Within Industry
Steam boilers are pressure vessels designed to generate steam by heating water using fuel sources such as natural gas, oil, coal, or electricity. The produced steam can be used for heating, power generation, or as a driving force for mechanical processes. Steam boilers are critical components in industries where reliable heat or energy transfer is needed, and they are built to strict safety standards due to the high pressures and temperatures involved in operation.
In industrial settings, steam boilers are widely used to provide process heat, drive turbines, and support manufacturing operations. In the chemical and petrochemical industries, steam is used for heating reactors, distillation columns, and other process equipment. Food and beverage manufacturing relies on steam boilers for cooking, sterilisation, pasteurisation, and cleaning processes, ensuring products meet hygiene and quality standards.
Power generation is another key industry where steam boilers are essential. In thermal power plants, boilers produce high-pressure steam to drive turbines that generate electricity. Biomass and waste-to-energy plants also use steam boilers to convert fuel into energy efficiently. In addition, steam boilers are used in paper production, textiles, pharmaceuticals, and oil refining, where heat and steam are integral to production processes.
Steam boilers are also used in commercial applications such as hospitals, hotels, and district heating systems, providing hot water, heating, and sterilisation capabilities. Modern boilers often include automated controls, energy-efficient designs, and safety systems to maximise performance and reduce operational risks. Overall, steam boilers are vital across numerous industries, supplying heat, energy, and process steam for a wide range of applications.
What’s Covered During Your SEIS Thorough & In Service Examination.
A PSSR (Pressure System Safety Regulations 2000) Thorough and In Service Examination of an steam boiler is a legally required examination to ensure the vessel is suitable for further service, and safe to used as part of the pressure system. If the vessel has a pressure x volume product greater than 250 bar/litres, and a relevant fluid is present within the system, or the vessel holds steam at any pressure, a written scheme of examination must be drawn up and certified. The competent person must carry out the examination in line with the written scheme of examination. Below is a details description of what is typically covered during a Thorough and In Service Examination;
 General Examination
Verification that the vessel complies with it’s manufacturers specifications and current legislation. Check all relevant documentation such as;
- CE/ UKCA conformity documents.
- Maintenance records.
- Previous hydro-static test pressure certificates.
- Previous reports of thorough examination.
- The written scheme of examination.
- Confirmation of all vessel markings (serial number, safe operating limit, design code, vessel volume etc).
 Structural Integrity
- Base of the boiler check the vessel supports and ensure vessel is securely affixed.
- Vessel shell (water side) check for no mechanical damage, erosion, scaling or excessive corrosion.
- Vessel lagging check the external of the vessel jacket and lagging.
- Panels check the integrity of any panels / guarding covering any integral parts.
- Mounting of system protective devices check for correct fitment and security.
- Man hole and mud hole doors check for integrity and spigot clearances are in tolerance.
- Steam pipework check the in-feed hose and steam feed pipework.
- Burner unit check structural integrity and check for security or damage.
- Water gauge glasses check for damage, wear, gland packings and they blow down correctly.
- Furnace and flame tubes check weld integrity and for any evidence of steam leaks / steam passing.
 Auxiliary Components
- Steam pipework and hoses check any hoses and pipework associated with the vessel.
- Blow down / drain valve check suitability, security and correct fitment.
- Economiser Internal and external examination, and check the associated system protective devices.
 Electrical System
- Electrical isolator switch check suitability and functionality.
- Pressure switch or pressure cut out check functionality during working examination.
- Level probes check for damage, functionality, electrical terminations and integrity of the switch.
 System Protective Devices
- Pressure gauge remove from vessel, check the threads, the gauge face, check for damage and test for calibration.
- Safety valve remove from vessel, check the threads, the valve face, check for damage and test for calibration.
- Pressure switch check the calibration of the pressure switch, and test functionality.
 In Service Examination And Functional Testing
- Allow system pressure to build and ensure the pressure cut out functions correctly.
- Pressure gauge reads correct and gives a smooth and accurate reading throughout its range.
- Gauge glasses blow down correctly.
- Carry out an accumulation test on the safety valve.
- Check functionality of any inhibitors, safety switches and stop buttons.
- Verify water level probe functionality.
- Burner lock out and flame detection device.
 Supplementary Tests
The competent person may use any, or all of the following supplementary tests to supplement their examination.
- Hydro-static pressure test.
- Ultrasonic thickness readings.
- non-destructive testing (NDT) by means of ultrasonic flaw detection, radiographic, magnetic particle or dye penetrant.
Common Defects:
- Manufacturers name plate illegible or missing.
- Pressure gauge damaged or out of calibration.
- Safety valve damaged or out of calibration.
- Level probes ineffective.
 Documentation and Reporting
After the inspection, the competent person will issue a PSSR Thorough Examination Report. This must include:
- Date of the examination
- Details of the equipment inspected
- Findings, including any defects
- Recommendations or required actions
- Date of next examination due
- Statement on whether the equipment is safe to continue using
If any serious defects are found that pose immediate danger, they must be reported to the duty holder and the enforcing authority (e.g., HSE) immediately.
 Summary
An steam boiler PSSR inspection ensures that your pressure systems are safe, compliant, and fit for use. It helps prevent accidents caused by damaged vessels, poor equipment practices and ineffective system protective devices. While it does not replace regular maintenance, PUWER and PSSR inspections are a crucial legal requirement for keeping pressure safe and avoiding costly breakdowns or incidents.
Why Steam Boiler Thorough Examinations Matter For You & Your Business.Â
Why PSSR2000 Thorough & In Service Examinations Matter
PSSR2000 thorough & in service examinations are a legal requirement in the UK for all pressure systems used at work and must be carried out in line with their written scheme of examination, and for good reason. These inspections ensure that pressure systems and their equipment, such as air receivers, pressure vessels, steam boilers, and other vessels containing a relevant fluid are safe to use, and fit for purpose. The nature of pressure systems and their associated vessels means that equipment failure can lead to catastrophic consequences, including serious injury, fatalities, and significant damage to property. By carrying out regular, scheduled thorough and in service examinations by a competent person, businesses can identify failure mechanisms, structural damage, or faulty system protective devices before they result in an incident.
Pros of Getting a Thorough and Working Examination in line with PSSR2000
Legal Compliance and Risk Reduction: The most obvious advantage is staying compliant with health and safety law. Compliance avoids potential legal action, fines, or even prosecution. More importantly, it drastically reduces the risk of workplace accidents caused by lifting equipment failure.
Improved Safety Culture: Regular inspections foster a proactive safety culture within the organisation. Employees are more likely to trust equipment and feel safe in their work environment when they know thorough checks are in place.
 Extended Equipment Lifespan: Regularly maintained and inspected equipment typically lasts longer. Examinations can identify early signs of damage or fatigue, allowing for preventative maintenance that avoids costly replacements or repairs.
 Insurance and Liability Protection: Insurers may require evidence of PSSR compliance in the event of an incident. Without valid inspection records, insurance claims could be denied or reduced, leaving the business liable for damages.
 Operational Efficiency: Detecting potential issues before they lead to equipment failure helps prevent unscheduled downtime. This keeps operations running smoothly and avoids the knock-on effects of delayed projects or interrupted workflows.
Cons of Failing to Carry Out PSSR Thorough and Working Examinations
 Legal and Financial Consequences: Failing to comply with PSSR can result in enforcement action from the Health and Safety Executive (HSE), including improvement notices, prohibition notices, fines, or even prosecution. Legal battles and associated costs can be financially crippling.
 Increased Risk of Accidents: Equipment that hasn’t been thoroughly examined is far more likely to fail. Such failures can lead to injuries or fatalities, particularly in high-risk environments like construction or manufacturing. Beyond the human cost, the reputational damage to a business can be severe and long-lasting.
 Higher Repair and Replacement Costs: Neglecting inspections can allow minor issues to develop into major faults. These may require costly emergency repairs or complete equipment replacement, expenses that could have been avoided through routine examinations.
 Loss of Business and Clients: Clients often expect their contractors or suppliers to uphold strict safety standards. A failure to meet legal obligations like PSSR can result in lost contracts or blacklisting from future work, especially in regulated industries.
 Increased Insurance Premiums or Invalidated Coverage: As mentioned, insurers may increase premiums or deny coverage entirely if a business can't provide evidence of up-to-date PSSR compliance, placing a heavier financial burden on operations.
PSSR thorough and in service examinations aren’t just a box-ticking exercise - they are an essential component of a responsible, safety-first approach to using pressure systems. The benefits of compliance are wide-ranging, from protecting human life to reducing costs and maintaining operational integrity. Conversely, the risks of neglecting these inspections can be devastating on multiple levels.
Key Points;
 Examinations must be carried out by a competent person - A competent person is someone with the right practical and theoretical knowledge and experience to conduct thorough examinations of pressure systems and their vessels and system protective devices.
Regulation 9 - Examinations in line with the written scheme
Key Points;
- Examinations of pressure systems which has a pressure x volume product of over 250 bar/litre, must have a written scheme of examination drawn up.
- The competent person must carry out the examination of the pressure system, in line with the written scheme of examination, using pressure system guidance and documentation to supplement their examination.
Key points;
 Examination Periods
- Examinations must be carried at set intervals noted in the written scheme of examination.
- SAFed guidance PSG 01 lays out guidance for the competent person as to when certain types of vessels should be examined. The vessel inspection periods can be determined by their process vessel category classification.
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Key points;
A report of thorough examination must contain the following
- The date the examination was undertaken, where the examination was undertaken and when the next examination is to take place.
- Means of identifying the pressure system (Safe operating limit, serial number, plant number, vessel volume, vessel location etc).
- Any findings, comments, defects and repairs noted by the competent person.
- Defects and repairs highlighting imminent danger must be reported to the relevant authority (HSE) within 28 days.
Great experience working with Oliver on the PSSR for our compressors! The team was very professional, knowledgeable, and easy to work with. They made the entire process smooth and stress-free. We would definitely use them again.
We’ve been using Statutory Equipment Inspection Solutions Ltd for our inspection needs, and their service is unmatched by any competitor we’ve worked with. They are extremely professional, always quick to respond to messages, and consistently provide prompt, detailed reports to help us stay compliant with regulations. Highly reliable and a pleasure to work with — we wouldn’t hesitate to recommend them.
SEIS have delivered LOLER and PSSR Thorough Examinations for us across Lincolnshire and Cambridgeshire with the utmost professionalism and the highest standards. With brilliant communication and a friendly, knowledgeable approach, we highly recommend their services.
Oliver at SEIS turned up on short notice to help us out after our current inspections provider let us down. He had our overhead cranes and fork trucks examined, and reports sent to us on the same day. Fantastic service.
The engineer surveyor SEIS sent was personable, and knowledgable. They was happy to work around our operational needs and examined our tailboard lifts with minimal disruption.
Thanks again!
Craig
Thanks again!
Craig