DE-AERATOR INSPECTION CHECKLIST V-603

De-Aerator
A thin layer of brownish colour covered with a black layer was
1 observed
inside the shell.
2 Minor pitting was witnessed on the shell.
4 Weld seams of man way
5 C.W seams of shell found
6 Jetting spring nozzle found misaligned
7 Joints of nozzle plate found cracked
8 Jet nozzle springs found ok
9 Corrosion / erosion were observed
10 P.T of weld seams carried out
11 MPI of 4-8 clock weld seam carried out
V-603 Accumulator
A brownish colour thick layer was observed on internal surface of
1 the shell
and overflow pipe.
Minor pitting and scale layer was also witnessed on shell and
2
internals.
Erosion on weld seam of 1½’’ Ǿ nozzle of level glass near the 2nd
3
C.W seam of shell was observed.
4 C.W & L.W weld seams of shell, man way and dish end found ok.
Bolts & nuts of support clamps of dozing line found loosened and
5
some were missing which caused vibration in line.
Welding of 4 Nos. down comers and their supporting ring with
shell, found
6 eroded. Supports of down comer pipes found thinned out. Pinholes
and
cracks were visible.
7 Erosion of welding seams was witnessed
8 Weld seams of over flow basins were eroded/ corroded.
9 Weld seams of nozzles found corroded/ eroded.
10 Weld seams of drain pits found corroded.
Thickness monitoring of both dish ends & shell, top nozzle Ø10" &
11 Ø24"
carried out and found ok.
12 North East Side - Dia. 10” / 24" down comer visual inspection
13 North West Side - Dia. 10” / 24" down comer visual inspection
14 South East Side - Dia. 10” / 24" down comer visual inspection
15 South West Side - Dia. 10” / 24" down comer visual inspection
16 MPI of 4-8 clock weld seam carried out

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 BOILER INSPECTION CHECKLIST B-602
Combustion Chamber
1 Refractory around Burners.
2 Refractory around man way.
3 Refractory behind the peepholes.
4 Refractory at riser tubes.
5 Refractory at floor.
6 Fin tubes - No sagging found.
7 Fin tubes - Minor reddish color layer
8 Burner tips found OK.
9 Burners fixed Vanes.
10 Thickness of C/C tubes. (5.0 mm)
11 Slight pitting
Super Heater # 01
1 Refractory at man way.
2 Refractory at top found cracked.
3 Some tubes with loose external deposits and hard scale accumulated.
4 Thick red color scale found on the tubes.
5 No corrosion / erosion observed on tubes.
6 Few tubes bowed and sagged.
P.T.of retaining rings of super heater man way conducted and
7
some repairs found in welding
8 No damage found due to overheating.
9 Some tubes found out of clamps.
10 Thickness of tubes measured. (Design = 4.5mm)
Upper row found plugged and flue gas by pass below the roof
witnessed.
Super Heater # 02
Tubes on both side walls found sagged and hanging and were not
1 on
hangers.
2 No corrosion / erosion observed.
3 No damage due to overheating.
4 Manhole refractory found detached from inside.
Refractory bricks of floor found loose and broken at some
5
locations.
6 Pieces of plugged & isolated tube found inside on floor.
7 A thick and hard scale accumulated on some tubes.
8 Thickness measured (Design = 4.5mm)
Super Heater # 3
1 Refractory firebricks of man way.
Hard deposits of scale on tubes and bends on West Side near man
2
way.
3 Thick layer of loose deposit found on most of the tubes.
Most of the tubes found entangled, loosed and were not on
4
supports / hangers.
5 Hot spots on retaining ring of man way observed.
6 Thickness of tubes. (Design = 5.5mm)
Steam Drum

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 BOILER INSPECTION CHECKLIST B-602
1 Scattered pitting observed inside drum (max. pit depth: 1mm)
2 Magnetite layer found “intact”.
3 Black loose dust layers found mostly in the lower half of drum.
4 Impingement plates for three nozzles found missing.
5 Thickness of Shell: 77.8~80.3mm.
6 Thickness of North Side Dish end (Design:50mm)
7 Thickness of South Side Dish end. (Design: 50mm)
8 Bolting arrangement.
9 All internals including Cyclone separator and plates.
Economizer
1 Inside surfaces with red deposits.
2 No corrosion was observed.
Front row of tubes (horizontal) found dislodged from their
3
supports.
4 Sagging of tubes was prominent.
A whitish deposit, thick layer was found on external surface of the
5
tubes.
No circumferential thru crack found at the toe of vertical down
6
comer to top ceiling weld.
7 No thru cracks noticed at economizer casing wall towards 02 area.
Welds between inclined and horizontal portion of bottom stiffeners
8 found
Visually ok.
Rings of top outer tubes found corroded from their inside
9
protruding ends.
Air Preheater (E-606)
1 Air preheater movement checked.
2 Condition of longitudinal seal.
3 Tack welding of plates.
4 Fins packets.
5 Circumferential and longitudinal seal.
6 Supports of Pinion rack.
Air duct before Preheater
1 Circumferential and longitudinal seals.
2 Fins packet (Heating Elements) in compact position.
Duct shroud plates, anchors and guide vanes found in satisfactory
3
condition.
Air duct after Preheater
1 Circumferential and longitudinal seals.
2 Fins packet (Heating Elements) in compact position.
Duct shroud plates, anchors and guide vanes found in satisfactory
3
condition.

Flue duct before Preheater

1 Presence of carried over dust.
2 Thickness measured.
3 Minor rusting witnessed on all surfaces.

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 BOILER INSPECTION CHECKLIST B-602
4 All supports found stable and firm.
5 Condition of Thermowells.
Flue duct after Preheater
1 Presence of carried over dust.
2 Thickness measured.
3 Minor rusting witnessed on all surfaces.
4 All supports found stable and firm.

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 BOILER INSPECTION CHECKLIST - B-601
Combustion Chamber
1 Refractory around Burners.
2 Refractory around man way.
3 Refractory behind the peepholes.
4 Refractory at riser tubes.
5 Refractory at floor.
6 Fin tubes - No sagging found.
7 Fin tubes - Minor reddish color layer
8 Burner tips found OK.
9 Burners fixed Vanes.
10 Thickness of C/C tubes. (5.0 mm)
11 Slight pitting
Super Heater # 01
1 Refractory at man way.
2 Refractory at top found cracked.
3 Some tubes with loose external deposits and hard scale accumulated.
4 Thick red color scale found on the tubes.
5 No corrosion / erosion observed on tubes.
6 Few tubes bowed and sagged.
P.T.of retaining rings of super heater man way conducted and
7
some repairs found in welding
8 No damage found due to overheating.
9 Some tubes found out of clamps.
10 Thickness of tubes measured. (Design = 4.5mm)
Upper row found plugged and flue gas by pass below the roof
witnessed.
Super Heater # 02
Tubes on both side walls found sagged and hanging and were not
1 on
hangers.
2 No corrosion / erosion observed.
3 No damage due to overheating.
4 Manhole refractory found detached from inside.
Refractory bricks of floor found loose and broken at some
5
locations.
6 Pieces of plugged & isolated tube found inside on floor.
7 A thick and hard scale accumulated on some tubes.
8 Thickness measured (Design = 4.5mm)
Super Heater # 3
1 Refractory firebricks of man way.
Hard deposits of scale on tubes and bends on West Side near man
2
way.
3 Thick layer of loose deposit found on most of the tubes.
Most of the tubes found entangled, loosed and were not on
4
supports / hangers.
5 Hot spots on retaining ring of man way observed.
6 Thickness of tubes. (Design = 5.5mm)
Steam Drum

Page 5 of 7
 BOILER INSPECTION CHECKLIST - B-601
1 Scattered pitting observed inside drum (max. pit depth: 1mm)
2 Magnetite layer found “intact”.
3 Black loose dust layers found mostly in the lower half of drum.
4 Impingement plates for three nozzles found missing.
5 Thickness of Shell: 77.8~80.3mm.
6 Thickness of North Side Dish end (Design:50mm)
7 Thickness of South Side Dish end. (Design: 50mm)
8 Bolting arrangement.
9 All internals including Cyclone separator and plates.
Economizer
1 Inside surfaces with red deposits.
2 No corrosion was observed.
Front row of tubes (horizontal) found dislodged from their
3
supports.
4 Sagging of tubes was prominent.
A whitish deposit, thick layer was found on external surface of the
5
tubes.
No circumferential thru crack found at the toe of vertical down
6
comer to top ceiling weld.
7 No thru cracks noticed at economizer casing wall towards 02 area.
Welds between inclined and horizontal portion of bottom stiffeners
8 found
Visually ok.
Rings of top outer tubes found corroded from their inside
9
protruding ends.
Air Preheater (E-606)
1 Air preheater movement checked.
2 Condition of longitudinal seal.
3 Tack welding of plates.
4 Fins packets.
5 Circumferential and longitudinal seal.
6 Supports of Pinion rack.
Air duct before Preheater
1 Circumferential and longitudinal seals.
2 Fins packet (Heating Elements) in compact position.
Duct shroud plates, anchors and guide vanes found in satisfactory
3
condition.
Air duct after Preheater
1 Circumferential and longitudinal seals.
2 Fins packet (Heating Elements) in compact position.
Duct shroud plates, anchors and guide vanes found in satisfactory
3
condition.

Flue duct before Preheater

1 Presence of carried over dust.
2 Thickness measured.
3 Minor rusting witnessed on all surfaces.

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 BOILER INSPECTION CHECKLIST - B-601
4 All supports found stable and firm.
5 Condition of Thermowells.
Flue duct after Preheater
1 Presence of carried over dust.
2 Thickness measured.
3 Minor rusting witnessed on all surfaces.
4 All supports found stable and firm.

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