PLANT MAINTENANCE

(ME-426)

Maintenance of Boilers

` Assistant Professor
Adeel Ahmed Khan,
(MED)
Boiler :
A closed vessel in which steam is produced from
water by combustion of fuel.
Purpose of boilers:
• Generation of Electric Power in steam power
plant
• Process requirements in Pharmaceutical for
mixing liquid, textile dyeing
• For heating the buildings in cold weather and
for producing hot water for hot water supply

2 Plant Maintenance ME-426

Primary requirements of a boiler:
• It must have a large heating surface so that the maximum amount of heat can be
absorbed.
• The water must be contained safely
• The steam must be safely delivered in desired condition (as regard its pressure,
temperature, quality and required rate)
• It should comply with safety regulations as laid down in the Boilers Act.
Factors while selecting a Boiler
• The quantity/quality of steam required and at what pressure and temperature.
• Floor area available.
• Type of fuel and water available.
• Accessibility for repair/inspection.
• Comparative initial cost.
• Operating & Maintenance costs.
3 Plant Maintenance ME-426
Classification of Boiler:
Boiler

According to According to According According

content in boiler type of firing to use to Pressure
According
to axis of According According to
shell to no of Circulation of
Fire tubes water
Water Internal External
Tube Tube High Low

Stationary Mobile
Vertical Horizontal Inclined
Single Multi Forced Natural

4 Plant Maintenance ME-426

Fire Tube Boiler:

5 Plant Maintenance ME-426

Water Tube Boiler:

6 Plant Maintenance ME-426

Boiler Mountings:
These are the fitting and devices which are necessary for the operation and safety of a boiler.
Types of Mountings
 Safety Valve

7 Plant Maintenance ME-426

Boiler Mountings:
 Safety Valve

8 Plant Maintenance ME-426

Boiler Mountings:
 Water Level Indicator:

9 Plant Maintenance ME-426

Boiler Mountings:
 Water Level Indicator:

10 Plant Maintenance ME-426

Boiler Mountings:
 Pressure Gauge:

11 Plant Maintenance ME-426

Boiler Mountings:
 Steam stop valve:

12 Plant Maintenance ME-426

Boiler Mountings:
 Feed Check valve:

13 Plant Maintenance ME-426

Boiler Mountings:
 Blow-off Cock/Valve:

14 Plant Maintenance ME-426

Major Causes of Boiler Failure:

 Low Water
 Poor Maintenance
 Failure of Controls and Safety Devices

15 Plant Maintenance ME-426

Low Water:
 Results in over temperature condition
 Can cause extensive damage to boiler
 Catastrophic failure of the boiler

 Low water is a condition that results when one of two things occur; the boiler requires
water but fails to call for it, or the boiler calls for water but fails to receive it.
 Low water itself is usually not a problem because the boiler is equipped with protective
devices designed to detect a low water condition and shut down the boiler before damage
can result.
 However, should these safety devices fail, or are not properly installed, or are non-
functioning, the results can be catastrophic.

16 Plant Maintenance ME-426

 Low Water:
• Fire tube Boiler that has
suffered a low water event.
• The furnace tube has
deformed and collapsed.

17 Plant Maintenance ME-426

 Low Water:
• Firetube boiler that has
suffered damage from
overheating caused by the
accumulation of scale
restricting heat transfer. This
causes the metal to overheat
and fail.
• Scale like this can be
prevented through a properly
developed and implemented
boiler water treatment
program.

18 Plant Maintenance ME-426

 Poor Maintenance:
• External corrosion resulting from a
leaking drain plug.
• This damage can lead to a failure of
the boiler when the metal becomes too
thin to contain the pressure inside the
boiler
• the boiler insulation jacket will need
to be removed
• the damaged area will have to cut out
to good metal and a new part
fabricated.
• After the repair has been made, the
boiler will need to be reinsulated.

19 Plant Maintenance ME-426

 Failure of Controls and
Safety Devices:
• Improper maintenance can result in
safety devices becoming non-
functioning.
• This relief valve has become blocked
with scale accumulations, it will
provide no protection against over
pressure.

20 Plant Maintenance ME-426

Failure of Controls and
Safety Devices:

A relief valve that has had the outlet nozzle capped off.

21 Plant Maintenance ME-426

Failure of Controls and
Safety Devices:

• A low water fuel cutout device

from a hot water heating boiler
showing the results of inadequate
maintenance.
• Sludge can form quickly
preventing the device from
working when needed.

22 Plant Maintenance ME-426

Lack of Maintenance:

23 Plant Maintenance ME-426

 Preventing Boiler Failure:

•Proper maintenance and proper operation go hand in hand.

•Proper maintenance practices must be followed in order to ensure the long
term reliable operation of the boiler.
“You cannot operate a boiler without properly maintaining it, neither can
you maintain a boiler without properly operating it.”

24 Plant Maintenance ME-426

 Boiler Operation:

• Prepare the boiler for operation

• Starting the boiler
• Regular operation
• Controls and safety valves
• Feedwater treatment

Boiler Codes:

• ASME Boiler & Pressure Vessel Code

• ASME Controls and Safety Devices
• Jurisdictional Rules

25 Plant Maintenance ME-426

 Boiler Logs:
•A fundamental, and often overlooked, part of an effective boiler maintenance program
involves continuous monitoring of the boiler’s operating condition.
•By paying attention to how the boiler is performing, its operating parameters, you can
develop information that will help you improve operational reliability, overall operating
efficiency, and increase operational safety.
•Many times, the information gathered will alert you to developing problems that, left
unattended, will result in extensive damage, unplanned outages, and costly repairs.
•What data should you collect, and how is this used?
 Pressures
 Temperatures
 Operational testing of controls and safety devices
 Water treatment

26 Plant Maintenance ME-426

 Jurisdictional Rules:
• Inspection Frequencies: how often are inspections required, power
boilers, heating boilers.
• Inspection types: internal or external
• Installation requirements: do the rules address installation, if so, review
these rules
• Rules for repair: review the rules for the repair of boilers, who can do
repairs, who must approve repairs, who must inspect repairs, etc…

27 Plant Maintenance ME-426

 House Keeping:
• Safety
• Fire Prevention
• Combustibles
 paint, oil, gas and cleaning products
• Flammables
 wood, paper and cardboard
 keep at least 8 to 10 feet from the boiler
• Emergency Access

28 Plant Maintenance ME-426

Control and Safety Devices:
• Pressure:
 The gage serves as an indicator of that pressure.
 Maintaining the pressure gage in an operable and accurate condition is essential to
safe operation.
• Temperature:
 Properly operating and accurate temperature indicators will allow operators to
determine if the controls are functioning and the boiler is within desired and safe
parameters.
• Water Level:
 Water level sight glasses must be routinely maintained in order to ensure the
accuracy of the sight glass.
 Low Water Cut Off devices are installed on all boilers to protect the boiler from this
most dangerous condition.
 Again, regular testing and maintenance is essential to their reliable operation.
29 Plant Maintenance ME-426
Control and Safety Devices:
• Combustion:
 Controlling the combustion of fuel is at the heart of operating a boiler.
 Regulating fuel combustion is used to maintain pressure or temperature at desired
levels.
 Most of the safety devices installed on boilers are designed to interrupt combustion
when adverse conditions are detected.

• Auxiliary Equipment:
 Fuel pumps, water pumps, air blowers, all are controlled by the boiler’s operating
controls
 This equipment will also have various indicating and control devices that must not
be overlooked in the overall maintenance of boiler controls and safety devices.

30 Plant Maintenance ME-426

 Boiler Maintenance:
General Maintenance:
 An inspection schedule listing the procedures should be established.
 It is recommended that boiler room log or record be maintained, recording daily,
weekly, monthly, and yearly maintenance activities.
 Even though the boiler has electrical and mechanical devices that make it automatic or
semi-automatic in operation, these devices require systematic and periodic
maintenance
 Any "automatic" features do not relieve the operator from responsibility, but rather
free him from certain repetitive chores, providing him with time to devote to upkeep
and maintenance.
 Only trained and authorized personnel should be permitted to operate, adjust, or repair
the boiler and its related equipment.
 Do not attempt to make repairs while the boiler is under pressure.

31 Plant Maintenance ME-426

 Boiler Maintenance:
Daily Maintenance:
 Operate the blowdown valve to remove any accumulated solids in the mud drum
 The valves on the water column and gauge glass should be operated to make sure these
connections are clear.
 Monitor water chemistry to adjust the chemical feed treatment and continuous blowdown
as required, to remain within water treatment guidelines established by the Owner's water
treatment consultant.
 Track boiler pressure and temperature
 Take a stack temperature reading to determine how efficiently the boiler is operating
 Check the incoming gas pressure in to the gas pressure regulator and also its downstream
pressure.

32 Plant Maintenance ME-426

 Boiler Maintenance:
Weekly Maintenance:
 Check the operation of the fuel supply valves
 Check the indicating or running lights and alarms to make sure they are functioning
properly.
 Assess the motors for noise and vibration.
 Look for leaks of fuel, water or flue gas.

Monthly Maintenance:
 Check the burner’s pilot tube that contains the electrode that provides the spark for pilot
ignition.
 Check the free movement of the air damper device or devices.
 Check the entire outside of the boiler for signs of hot spots.
 Test the boiler safety valves in accordance with the manufacturer's instructions to be
absolutely sure that the valves have not corroded shut.
33 Plant Maintenance ME-426
Boiler Maintenance:
Annual Maintenance:
 Properly shut down the boiler and open the access doors to expose the fireside of the boiler
 Thoroughly clean the tubes and tube sheets.
 Use a hand scraper to remove accumulated sludge and scale.
 Start near the top and work toward the bottom.
 After cleaning tube exteriors, inspect the tube surfaces for signs of overheating, such as
bulging, blackened surfaces in the tubes, etc.
 Inspect the insulating materials, looking for any degradation.
 Check for cracks in refractory insulation. Cracks of 1/8” or less are okay.
 On the waterside, look for heavy scaling and tubes with scale.
 Check the gas valves and conduct the safety test recommended by the valve manufacturer.
 Check the safety valve to make sure there is no sign of leakage
 On the control panel, ensure that all of the electrical connections are tight.

34 Plant Maintenance ME-426

 Boiler Maintenance:
Annual Maintenance:
Inspect accessories such as the feed water receiver, deaerator and chemical feed systems, if
these are part of the boiler system

Replacement of flange, manway, and hand hole gaskets

1. Clean metal surfaces where cover plate bears against shell plate or ring.
2. Always use new gaskets and use graphite paste to gasket to prevent sticking and assure
tightness.
3. Spare gaskets should be maintained in your inventory to minimize your downtime.

35 Plant Maintenance ME-426

 Annual Inspection:
• Insurance regulations or local laws will require a periodic inspection of the pressure vessel
by an Authorized Inspector
• Sufficient notice is generally given to permit removal of the boiler from service and
preparation for inspection.
• This major inspection can often be used to accomplish maintenance, replacements, or
repairs that cannot easily be done at other times. This also serves as a good basis for
establishing a schedule for annual, monthly, or periodic maintenance programs.
• While this inspection pertains primarily to the waterside and fireside surfaces of the
pressure vessel, it provides the operator an excellent opportunity for detailed inspection and
check of all components of the boiler including piping, valves, pumps, gaskets , refractory,
etc.

36 Plant Maintenance ME-426

 Annual Inspection:
• Comprehensive cleaning, spot painting or re-painting and the replacement of expendable
items should be planned for and taken care of during this time.
• Any major repairs or replacements that may be required should also, if possible, be
coordinated with this period of boiler shutdown.
• Replacement spare parts, if not on hand, should be ordered sufficiently prior to this
shutdown.
• Have available information on the boiler design, dimensions, generating capacity, operating
pressure, time in service, defects found previously, and any repairs or modifications.
• Also have available for reference records of previous inspections.
• Be prepared to perform any testing required by the inspector including hydrostatic testing of
the equipment.

37 Plant Maintenance ME-426

Boiler Hydro Test :
• The main purpose of hydro test is to ensure all the welding joints, pipe bents and all headers are water leak
proof.
• The hydro test is generally done at a pressure of 1.5 times of design pressure, For example if a boiler is
designed with maximum working pressure of 50 bar then the hydraulic test pressure will be 75 bar.
• The hydraulic test is done and certified with the presence of factory/boiler inspector.
PRE CHECK LIST HYDRO TEST:
1) All erection work should be completed.
2) Confirm that no foreign material or loose material left in the boiler.
3) Confirm the drum manhole is closed with proper gasket.
4) Confirm all the drain system ready for operation.
5) All safety valve should be Gagged.
6) The range of the pressure gauge should be two times of the maximum test. pressure but not less than test
pressure.
7) The pressure gauge should be pre calibrated before test.

38 Plant Maintenance ME-426

Boiler Hydro Test :
PRE CHECK LIST HYDRO TEST:

8) The test pump pressure should have capacity of more than test pressure.
9) The test pump should have pressure gauge, check valve , drain valve
10) Minimum quantity of DM water should be available equivalent to the boiler capacity.
11) Ensure Condensate & FW chemistry parameters to strictly adhere to the required standard.
12) The PH value should be in the range of 8 to 9.
13) The water temperature shall be not less than 21.1 deg oC.
14) Isolate all pressure and temperature gauges except some pressure gauges for hydraulic pressure
measurement.​

39 Plant Maintenance ME-426

Hydro test Procedure :-
1) Start the boiler filling with the filling pump through the drain header or filling line.
2) Close the all vents sequentially after water coming from the vents.
3) Start the hydro test pump (ensure all vents closed) and rise pressure gradually to the design pressure and then
the pressure to be raised up to test pressure.(For example if the design pressure is 200 bar then the test pressure
should be 300 bar ;1.5 times of design pressure)
6) Hold the pressure raising at 50 bar & 100 bar, to check any valve passing & inspect leakage in pressure
parts.
7) Once the pressure reached to test pressure stop pressurizing and observe pressure drop if the pressure drop is
very less then the test is success.
8) If any defect is found, same to be noticed and taking account the type of defect and solved later.
9) If the pressure is holding better then de pressurizes pressure @ 50 bar by opening top vents.
10) After de pressurize allow check team for physical inspection of inside boiler.
11) After satisfy test, documents to be prepared and signed with the concerned authorities.

40 Plant Maintenance ME-426

Diagnostic Tools:
Combustion analyzer :
• A combustion analyzer samples, analyzes, and reports the combustion efficiency of most
types of combustion equipment including boilers, furnaces, and water heaters.
• When properly maintained and calibrated, these devices provide an accurate measure of
combustion efficiency from which efficiency corrections can be made.

Thermography:
• An infrared thermometer or camera allows for an accurate, non-contact assessment of
temperature.
• Applications for boilers include insulation assessments on boilers, steam, and condensate-
return piping. Other applications include motor/bearing temperature assessments on
feedwater pumps and draft fan systems.

41 Plant Maintenance ME-426