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2. Jenis-jenis Selenggara
Penyelenggaraan Pembetulan (corrective)
penyelenggaraan pencegahan (preventive)
penyelenggaraan ramalan (predictive)
4. Activities
Routine service (preventive)
Repair (corrective)
Inspection (preventive/predictive)
Overhaul (predictive)
5. After 5-6 months of the boiler operation, the boiler should be down for maintenance.
(1) To clean off the deposits in the drum, headers of the boiler
(2) To clean off the soot on the heating surface.
(3) Inspection on the internal or external sections of the boiler, such as check of the
welds of the pressure parts and steel sheets for corrosion. Severe defects shall be
subject to immediate remedy action. If the suspicious defects are located but not
impacting the safe operation, records shall be taken for future reference.
(4) Check the induced draft (ID) fan for bearing abnormality, check the impeller and the
casing for wears and tears. The user shall keep sufficient spare parts for the
impellers.
(5) Some portions of the boiler walls can be removed for thorough inspection, if
necessary. When the inspection locates the serious damage, the complete repair has
to be carried out before start up. All the findings from the inspection and the repairs
after the inspections shall be entered into the boiler safety technical logs.
(6) Preservation for the boiler out of service for a long time:
a. Water preservation:
fill up the boiler with the treated water, and then boil up the water to
remove the air. Fully close all the doors and openings. Or fill up the boiler
with the de mineralized water of high alkalinity to prevent the corrosion.
The chemicals added into the de mineralized water usually are NaOH
(2kg/mᶾ) or Na₃PO₄ (5 kg/mᶾ), and that added into the boiler water are
NaOH (5 kg/mᶾ) or Na₃PO₄ (15-20 kg/mᶾ). This method is only for short time
shutdown preservation with the heating surfaces and the boiler walls
properly dried.
b. Pressure preservation:
After removal of deposits from inside the boiler, all the valves shall be
closed. Preservation solution is to be added up to the lowest point of boiler
outlet header. Heat up the boiler to create a pressure of 0.1-0.2MPa, and
then hold the pressure for 2-3 hours. After pressure is dropped down, the
preservation solution should be used again to fill up the boiler, and then
keep the pressure of 0.2MPa by using a hydraulic way. The preservation
solution is composed of caustic soda (100mg/L), phosphorus pent oxide
(100mg/L), sodium sulfate (250mg/L). During the preservation period,
regular inspection for the proper concentration of the solution is required.
When the concentration of sodium sulfate is found to be lower than 50mg/L,
more of that chemical shall be added to keep the specified concentration.
c. Nitrogen preservation(omitted)
When the boiler is down for a quite long time, the nitrogen preservation
can be applied.
Draining of Condensate
a) Remove water in steam pipelines, its can lead to water hammer.
b) Steam and slug of water travel at a very high velocity hit any obstruction
downstream and can result in severe damage, for example:
7. Maintenance Inspection
Dimensional
Erosion, corrosion, abrasive wear, deformation changes due to stress, cavitation
Distortion
Abstructed expansion, overheating, unequal expansion, overstress
Cracks
Fatique, thermal stress, water hammer, improper welding, poor design
Deposits
incomplete combustion, rust deposits, dusty condition, upstream sootblowing and etc
Blockage
Accumulation of scales, soot, foreign matter, damaged strainer
PEMERIKSAAN DANDANG (INSPECTION):
Who
Why What
Boiler
Inspection
How When
Where
PIC SB/UPV must notify inspector in writing, which may affect safety or strength
SB/UPV
Loss boiler water, melting of fusible plug and tube burst
Qualified Qualified Who Will
DOSH Insurance Authorised
3rd party owner's Do
Inspector Inspector Inspector
inspector inspector Inspection?
What?
Destructive
Test (DT)
What?
• Specimen of part of boiler
taken and tested to it's limit
to destruction
• DT Method: Tensile, Bend,
Charpy, Hardness, Fatigue,
Creep, Metallography and
chemical analysis
Boiler Inspection
• FMA 1967, (Notification, Certificate of fitness and inspection)1970
• Regulation 13, 14 and 17
Furnace
• Front wall tubes including area of burner Furnace floor area
• Side wall tubes including peephole area Rear wall tubes including boiler nose area
Secondary Superheater & Reheater
• Secondary superheater tubes Secondary reheater tubes Boiler roof
• Screen tubes Manhole and sootblower area
Tubes
• Cutting of tubes for inspection and rewelding
• Replacing worn-out tubes
Valves and Fittings Feedwater control valve and its bypass High pressure dosing valves
• All safety valves Isolating valves of burner inlet and outlet
• MSV and its bypass Boiler and drum blowdown valves
Economizer
•Interior tubes and headers (corrosion, oxygen pitting and scale) Cleanliness and security of vent and drain
•Exterior tubes and headers (corrosion, erosion and deposits) connections valves
•Soot blower (impingement and leakage) Exterior casing for leaks and tightness and doors
Feedwater Regulator
Check leaks, operability and cleanliness
Do not dismantle if operation satisfactory
Check connecting lines and mechanism for proper function
• Burner throat refractory
• Pit refractory
Refractory • Slag build up on refractory
• Missing Insulation on
•Check extend expansion and headers and drum
contraction of pressure parts
during startup and shutdown
Furnace
•Check header support hangers
always in tension. Looseness and Casing • Burner wear by observe
indicate obstruction to free flame shape and
expansion and contraction completeness of
Burner combustion
• Ease of operation burner
•PSV dissembled and check for vanes, indicate burner
any surface discontinuity at mechanism condition
seat PSV. If any discontinuity
Pressure
presence, remove it via lapping Safety
or changing faulty internal etc Valve
•Assemble and do leak test
using method : pnuematic pop (PSV)
test/water leak test • Check for change of
Superheater pressure drop through SH,
Tubes indicating to internal
condition of tubes
•Check temperature differences
over two units at constant load.
Indicate deposits/ build up Economizer
•Check pressure drop over any part and air pre- • Check steam quality,
of system at constant load,
indicating misplaced/ bypassed
heater indicate condition of steam
baffle scrubbers and separators
Boiler
• Check noises in drums.
Drums
Maybe caused by loose
connections of drum
internal piping