PENTHOUSE

PENTHOUSEAIR-IN
AIR-INLEAKAGE
LEAKAGEON
ON
BALANCED DRAFT BOILERS
BALANCED DRAFT BOILERS

UDC
MACT
WORKSHOP
 Introduction
Introduction
●
Air-In Leakage
•Evidence is found during Visual Inspections

•Percentage of leakage is a critical variable

•Multiple sources may be contributing factors

•O2 Probe Monitoring

Combustion Air
Tramp Air
UDC
MACT
WORKSHOP Elimination of Air-in leakage results in-
True O2 Monitoring
Greater Unit Efficiency
Optimum Combustion Performance
 Sources (Sites) of Air-In Leakage
Sources (Sites) of Air-In Leakage
●
GOAL - Mitigate or Eliminate Air-In Leakage

Inspection Techniques

• during unit operation

• during planned maintenance overhauls 

Boiler Design Air-In Leakage Avenues

• improperly sealed access doors or observation ports

• deficient refractory and boiler seal casing
• cracked sections of ductwork & expansion joints
• poor air pre-heater seals
 
Primary Areas of Concern for Leakage
 
UDC Main furnace
MACT Penthouse floor pan casing, tube penetration seal boxes, and roof/ sidewalls
Pendant section areas
WORKSHOP Extended sidewall and convection pass areas
Ductwork spanning from economizer to APH
Air Pre-Heater
Ductwork after APH spanning to ID fan
 
 Typical Penthouse Deficiencies
Typical Penthouse Deficiencies
●
Routine Penthouse Inspections
Balanced Draft Positive Pressure Boilers

Typical penthouse damage linked to air-in leakage include

 
Deteriorated roof tube peg fin and underlying refractory (as viewed from furnace side)
Deteriorated floor pan casing and seams in the form of cracks and voids
Tube penetration seal box damage (crown & non-crown)
Header enclosure seal box damage
Cracks and voids adjacent to roof tube support plates and seal box end caps
Damaged expansion joints (collapsed, elongated, cracked, blown-out, etc.)
Open areas or voids in lagging sidewalls of penthouse
Deficient seals and/or voids around supports and hanger rods to boiler roof steel
 
UDC
MACT
WORKSHOP
 Preferred Repair Method
Preferred Repair Method
●
 
 
Permanent Repair
Holistic Approach
Sectional Casing or Seal Boxes Affected
should be replaced

Sagging or Bowed Roof Tubes or Absence of Peg Fin and Refractory

UDC should be replaced

MACT
WORKSHOP
*Seal Welding or Plate Repair are NOT the recommended repair method
 Picture Set ‘A’
Picture Set ‘A’
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UDC
MACT
WORKSHOP
 Picture Set ‘B’
Picture Set ‘B’
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UDC
MACT
WORKSHOP