ISGEC John Thompson

SECTION-15

MAINTENANCE OF
BOILER
 ISGEC John Thompson
SECTION – 15

MAINTENANCE

15.1 KEEPING THE BOILER CLEAN

15.1.1 Internal Cleaning (Heating Surfaces)

Correct treatment of both feed and the boiler water will
ensure the internal cleanliness of both drums and
heating tubes between overhaul periods.
15.1.2 External Cleaning (Heating Surfaces)
When a markedly different draught loss is observed
compared with previously recorded figures for similar
boiler conditions, this will indicate that fouling has
advanced to a stage where external cleaning by wire
brushing is necessary.
This will require the boiler to be shut down for a period
sufficiently long for a thorough cleaning and inspection.
Particular attention should be given to places where soot
and moisture will collect such as the bottom bends of
tubes entering mud drum, since this will accelerate
corrosion.

15.2 TUBE REPAIR

15.2.1 Expanded Tubes
Faulty tubes are cut off local to each end, the stubs
remaining are then trimmed and driven into the drum or
manifold from where they are retrieved.
A new tube is prepared and expanded in position in the
manner described in 15.3 below. AVOID DAMAGE TO
TUBE HOLES.

15.2.2 Welded Tubes

Faulty tube sections are simply cut out and new sections
welded in. The relevant drawing must be consulted to
ascertain the correct weld preparation and welding
technique, material etc. to be used.

15.3 METHOD OF EXPANDING TUBES

a) Clean the new tube inside and out to remove any protective
coating, scale or rust.
b) Remove any roll or die marks from the tube ends. These
must be smooth and washed with a highly volatile grease

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 ISGEC John Thompson
solvent (as carbon tetrachloride) to ensure that they are
clean and dry.
c) Clean the tube seats in the drum or manifold in similar
manner.
d) Select a tube expander to suit the diameter and thickness of
the tube and the width of tube seat. The length of the rollers
should be sufficient to expand the tube to a diameter ½ “ or
more greater than the tube diameter dependant on the gauge
of the tube.
e) Insert the tube in the seat and set the inside projection to
that specified on the relevant drawing.
f) Insert the expander sufficiently far into the tube to allow the
small end of the belling roller to enter then withdraw the
expander sufficiently to ensure that a reasonable amount of
expansion takes place before belling commences.
g) Turn the mandrill, the expander will progress into the tube
until the collar abuts on the tube end. Expand the tube
slowly to avoid overheating. It is preferable to under-roll
rather than to over-roll a tube since if a subsequent
hydraulic test shows up a leak it is to be tightened by an
additional roll. An over-rolled tube however would have to
be removed and replaced by a new tube.
Over rolling will be evidenced by flaking of the tube metal
under the rollers.
Where straight rolling expanders are used the belling is
done with a hand belling tool.
Avoid excessive lubrication of expander. Do not use mineral
oils. Recommended lubricant is undiluted SHELL FRI 6
Soluble oil which is easily removed by the boiling out
process.

15.4 BRICK & REFRACTORIES

Every opportunity should be taken to inspect the brick work
inside the boiler for general condition, erosion and formation of
cracks.
Care must be exercised when removing deposits from the faces
of the walls to ensure that damage is not caused to the brick
work and refractory.
Any damage incurred or discovered must be repaired by cutting
or grinding out the crack or eroded portion to form a key for the
repair to be effected with plastic refractory .Use a mallet or
wood block to ram the refractory well into the recess. Adhere
strictly to the maker’s instruction for mixing and applying the
refractory material.

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 ISGEC John Thompson
Small holes penetrating into the material will help in the drying
out by allowing moisture to escape. ¼” dia needle should be
used for this, making holes at 8” centers to a depth of about 2”.
Drying out after repair must be done according to the procedure
outlined in SECTION 7. The fact that there may only be small
areas to dry is irrelevant since the time factor is not related to
the volume of refractory used; one brick will take as long to dry
out as a whole wall.
When selecting the type of plastic refractory to use for repairs
local to steelwork, those grades having a high conductivity
should be avoided, since they will not afford adequate
protection against burning. This is especially important where
the steel has no insulating material immediately next to its
surface.
15.4.1Care Of Refractory Materials
These must be stored in a clean, dry place where they are not
likely to be disturbed and where they are not likely to be
contaminated by oils or grease which will destroy their bonding
properties.
15.5 VALVES AND VALVE SEATS
These are usually of such design as to allow repeated
reconditioning of seats by facing or lapping depending on the
seat condition. Do not attempt to lap out deep blemishes. Time
can be saved by refacing, followed by a final lap.
Valves and seats must be lapped independently using suitable
lapping plates. These should be kept perfectly flat and should
be renewed upon if any signs of wear becoming apparent.
Lapping abrasives should be used, the natural porosity of the
lapping plates will retain all that is necessary to produce a
finished surface.

15.5.1 Lapping Equipment

a) Two large grinding plates are provided for lapping the

various discs for valves of all sizes. These plates are used
also for reconditioning the plates used for lapping the valves
seats. When reconditioning the lapping plates it is necessary
to remove the pilot piece in order that the plate can be laid
flat on the grinding plate. The pilot piece is replaced after
reconditioning.
b) Safety valve heads cannot be lapped on the flat grinding
plate; a set of special plates for this purpose is therefore
provided on request.
c) A complete set of lapping plates to suit all sizes of valve seats
is supplied on request.

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 ISGEC John Thompson

15.6 AUXILIARY EQUIPMENT

Correct maintenance procedures and operating
recommendations for the various auxiliaries will be found in the
subsequent operation & maintenance manuals.

15.7 LUBRICANTS
A complete and adequate supply of lubricants must be available
at all times. The grades recommended by the various makers of
the auxiliary equipment in their literature MUST be adhered to
if their warranties are to be taken advantage of.

15.8 TREATMENT OF SCREW THREADS

All threads must be treated with a suitable lubricant on
assembly to facilitate disassembly and prevent corrosion. This
is especially important where bolts and studs are exposed to
high temperatures and pressures, which promote a welding
action.
Such conditions are prevalent with fixtures inside drum such
as baffles, cyclones pipe supports and flanges etc... also with
manlid and handhole cap studs, where temperatures are in
excess of 121 o C.
Upon initial erection all screw threads are properly treated, and
during subsequent maintenance it is advised that they are re-
treated as a matter of normal routine.
For normal applications MOLYBDENUM DISULPHIDE grease is
perfectly satisfactory.

MAINTENANCE SCHEDULE

1 STEAM DRUM

Operational Checks:

Check for steam and water leaks from connections and fittings to the
drum.

Prior to Shutdown:

Check drums pressure gauges, safety valves water level gauges for
accuracy & reliability.

Annually:

Inspect the drum internally for evidence of the following:

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 ISGEC John Thompson
 Surface cracks or grooving
 Carryover
 Any sign of oil or other substances that may have entered the
boiler.
 Signs of pitting
 Sludge or scale accumulation
 Corrosion
 Clean out any debris that has accumulated inside the drum.
Remove any scale and sediment.
 Inspect for a noticeable and smooth water level.
 Inspect the drum shell between tube openings (ligaments) for
pitting or cracking.

Check for and clean any scale or sludge in the following areas.
 Primary scrubber elements.
 Feed water line.
 Continuous blow-down line.
 Chemical feed line.
 Openings to safety valves must be free of obstructions, such as
mud or scale

Repair the following if any trace of leaks or obstruction has been

found during operation.
 Connections to blow-down
 Connections to water columns and level gauges.
 Connections to pressure gauges
 Connectional to transmitters

Inspect the drum internals to ensure that joints in the following areas
are tight.
 Steam cyclone separators.
 All baffles.
 Steam scrubbers.
 Chemical feed and blow-down lines.
 If chemical cleaning has been performed, inspect for improper fit of
internals.
 Ensure all flanges and corrugated plate sections are seated
properly.
 Mark all adjusted internals for future removal and reinstallation.
 Inspect and replace manhole gaskets if damaged or deteriorated.
 Remove all drum internals and inspect for wear ,corrosion &
erosion.

2 HEADERS

Annually
 Inspect header caps/flange joints for signs of leaks or cracking by
DP test.

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 ISGEC John Thompson
Every Five Years:
Check headers for the following.
Corrosion.
Inspect for cracking of welds in the areas listed below using non-
destructive testing method.
 Tube to header welds.
 Header shell between tubes (ligaments).
 Nozzle to header welds.
 Thermo-wells.
 Lug and hanger connections.
 Hand-hole fittings.
 Longitudinal and circumferential welds.
 Drain connections.
 Cracking in safety valve opening.

3 FURNANCE

Operational Checks:

If possible, inspect the slagging condition of furnace walls through

ports. Use extreme caution when doing so. Always wear tinted goggles
or shield to protect eyes from harmful light rays, slag or ash particles.
Do not stand directly in front of open ports.

Walk around the exterior and observe for any hot spots or gas leaks.

Prior to Shutdown:

Check for gas leaks at observation ports, as well as manhole and

access doors. Note or mark any areas in which leakage is occurring
(for ease of location during shutdown).

Annually:

 Inspect the tube surfaces for signs of leaking, corrosion,

overheating (blistering and bulging), warping, misalignment,
pitting, or cracking.
 Inspect all wall tubes in the vicinity of soot-blowers for erosion.
Pad-welded and correct position of blower nozzle in relation to
eroded wall tubes if any.
 Inspect furnace side wall at junction of furnace and convection
pass for cracking due to differential expansion.
 Inspect furnace rear wall to arch junction for casing leaks.
 Ensure baffles are in place and healthy condition.
 Inspect for cracking of membrane bar at field panel splits.
 Check the condition of all refractory.
 Locate any deposits of ash or slag not removed by soot blowing,
which may effect heat transfer or block gas passage through the
unit.
 Clean and reset manholes. Inspect condition of gasket.

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 ISGEC John Thompson
 Inspect the condition of seal around doors and openings.
 Inspect the inner surfaces of furnace wall tubes for deposits and
scale.

Every 5 years:

Take random ultrasonic tube thickness measurements in critical

locations, such as:
 At furnace rear wall headers.
 Lower furnace wall tubes.
 Around soot-blower openings.
 Around burner opening,if provided .
 In furnace corners.

4 SUPERHEATER /BED COILS / WING WALLS

Annually:
Externally inspect tubes for signs of

a) Overheating (swelling or blistering)

b) Warping
c) Misalignment
d) Corrosion
e) Fouling
f) Erosion
g) Gauges (due to tube leaks in surrounding area)

 If internal deposits are suspected, tube section should be

removed for inspection, the determined and corrected prior to
returning to service.
 Inspect support system.
 Check attachment to tube welds for cracking or wear.
 Inspect the condition of super heater seals where the tubes
penetrate the furnace roof.
 Check attachment to tube welds for cracking or wear.

5 ECONOMIZER

Operational Checks:

 Listen for any unusual noise around the economizer section,

which may be indicative of an economizer leak (i.e. hissing)
 Inspect hoppers to make sure they are emptying properly.

Prior to Annual Shutdown :

Perform soot blowing in the vicinity of economizer tubing.

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Annually :

 Visually inspect economizer to locate any deposits not removed

by soot blowing that may interfere with hear transfer or block
gas paths. The presence of such deposits is an indication that
operation and blowing pressure of soot blowers should be
checked.
 After visual inspection, determine if cleaning is necessary.
Cleaning of economizers is the same as for air heater. Perform
a water wash directly after shutdown using a warm alkaline
solution with a pH level between 10.5 and 11.0

 Externally inspect tubes for sings of:

1. Overheating (swelling or blistering)

2. Warping
3. Misalignment
4. Corrosion
5. Fouling
6. Corrosion

 If pitting has been found in the steam drum take economizer

tube sample and inspect them internally for pitting.

 If internal deposits are suspected, tube sections should be

removed for inspection, the cause determined and corrected
prior to returning to service.

 Check for erosion around spacer bars and lugs.

 Check attachment to tube welds for cracking or wear.

 Inspect attachment to tube welds for cracking or wear.

 Inspect economizer hopper trusses and gusset plates for

erosion and corrosion damage.

6 HOPPER

Operational Checks :

Inspect for air leaks around the hopper.

 Inspect for signs of overheating that may indicate wind box

fires.
 Review the pressure drop between the hopper and furnace
regularly.
 Changes in this pressure for a given load condition may
indicate for restriction problems within the.

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 ISGEC John Thompson

Annually:

 Inspect hopper for accumulated build up to fuel/ash.

 Inspect all internal baffles, tie-bars and trusses to ensure they
are in good condition.
 Inspect for bowed tie-bars and trusses caused by overheating
or over pressure.
 Excess tension, slackness or deflection of these components
should be reviewed for potential expansion problems.
 Check to ensure that the dampers are cleans and free to
move. Lubricate all moving parts with a high temperature anti-
seize compound.
 Inspect hopper corners and expansion joints for signs of
cracking or tears.

7 FLUES GAS PATH DUCTS AND DAMPERS

Operational Checks:
 Check around all ducts and flues for signs of leakage.
 Check position of fan dampers.

Annually:

FLUE GAS PATH

Check flue gas path for the following.

 Gas tightness
 Disengagement or misalignment of support hangers and
supporting rods
 Tightness of the mounting hardware
 Corrosion and erosion on inner surfaces
 Excessive deposits of dust and ash

 Inspect all refractory surfaces exposed to flue gases.

DUCTS

 Check ducts for the following:

 Air tightness
 Disengagement or misalignment of support hanger and
supporting rods
 Tears and cracks at wind box corners.

DAMPER

Check air damper for the following :

 Air leakage through damper spindle bearings

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 ISGEC John Thompson

 Sticking operation of control dampers over the control range

 Tightness of shut off dampers

 Inspect flue gas dampers for the following

 Dust leakage on damper shaft packing glands

 Warpage
 Overheating
 Any sticking operation of control dampers over the control
range
 Tightness of shutoff dampers

 Lubricate all drives.

 Examine damper assemblies for wear of blades and blade spindles.

Ensure vanes are free to operate. Grease all joints on bearings.

8 EXPANSION JOINTS

 Inspect the internal and external condition of all expansion

joints (especially non-metallic types). Determine if any unusual
wear or pluggage has occurred.

 Inspect for warpage or cracks.

 Clean expansion joints of excessive dust collection to allow

proper flexibility

9 SUPPORTS

Prior to Annual Shutdown:

Inspect external areas of boiler for damaged support equipment. By

taking a walk around piping systems, and indication of support and
supported equipment, condition can be obtained. This will aid in the
formation of a shutdown maintenance schedule.

Annually :

 Inspect boiler for alignment, noting any abnormal movement

 Check condition of header guides and supports to ensure
alignment yet permit expansion of tubes without excessive
strain

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 Check that main steam piping and connected equipment are

properly aligned and have proper clearance for expansion
 Inspect for sings of support failure such as insulation damage
and changes in scale readings on flexible type supports.
 On spring type hangers, check for broken spring. Measure and
record spring lengths.
 Inspect support for tubes off of compression supports,
compression support burn-back, support lug failure, and
lower tube sag.
 Check piping supports and hangers for disengagement or
misalignment. Verify each hanger is carrying load.
 Inspect hanger rods for tightness.
 Check for corrosion of hanger components, including tube
spacers and support saddles. If corrosion is found, apply a
rust inhibitor.
 Look for broken or cracked hanger rods, pins, lugs, ties or
saddles. Tighten any loose nuts.
 For constant support hangers, inspect levers and remove any
fly ash deposits found. Re-pack with greases.
 Inspect drum and down-comer hydraulic shock arrestors for
damage. Check the fluid lever and look for fluid leakage.

Every 2 Years :

Inspect buck-stays for straightness and their attachment to furnace

walls.

Every 5 Years :

Perform visual and magnetic particle inspection of support ties,

saddles and attachment weld.

10 REFRACTORY AND INSULATION

Operational Checks :

 Inspect around all air and gas passages for possible air or gas
leaks.
 Inspect around the boiler casing for gas leaks or hot spots.

Annually :

 Inspect the condition of the refractory around spreader throats

and surrounding wall area. Repair or replace as necessary.
 Inspect the condition or refractories on furnace walls, front
plate and around corner sections. Visually check if cracks
have formed and if the cracks have crossed one another
enough to cause a section to fall off.

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 ISGEC John Thompson

 Inspect the refractory in the ash hopers off damage.

 Inspect the condition of the refractory around access doors
and observation ports.
 Inspect the refractory seal wherever tubes penetrate the
furnace roof.
 Inspect for wear or loss of retainer plates around tube through
roof penetrations.
 Inspect the condition of refractory seals wherever tubes
penetrate walls.
 Inspect the condition or baffle wall seals.
 Inspect the condition or refractory surface exposed to flue
gases.

11 SAFETY VALVES

Operation Checks :

 Check for leakage at valves by audio-visual inspection, at

normal operating pressure.
 Check the clearance of the lifting lever on the leaking valve.
Note and log the severity of leakage.
 Check drain lines and drip pans are not plugged.
 When safety valves do operate, note the opening and resetting
pressures as accurately as possible. After normal operating
pressure has resumed, check for leakage at valve. Incorrect
setting will require adjustment.
 Note the severity of any leaky safety valve.
 Assess leakage rate from weekly checklist if a noticeable
increase has occurred. Plant for an early shutdown to repair.
Early shutdowns can reduce damage to valves.

Annually :

Clean internal parts, there should be no accumulation of rust, scale

or other foreign substances, which will interfere with their free
operation.
Clean exterior of fly ash, fuel, dust, etc.
Recondition valve seats (laps).

REFER MANUFACTURE MANUAL FOR DETAIL OVERHAUL

12 BOILER VALVES
Operational Checks:

Make note of any leaky valves and prepare a report.

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 ISGEC John Thompson

Annually :

 Check seating surfaces of body and disc for flaws or cracks. Re-
lap if repairable.
 Examine the back seat for erosion and corrosion. Replace if
erosion is too deep.
 Inspect the gasket between body and bonnet for dents, friction
flaws, erosion and corrosion. Repair gasket seat by sand paper or
lapping. If a flaw still exists in the redial direction, discard and
replace.
 Check the stem for cracks, were, flaws deflection, deformation
and erosion of packing contact section. If cracked, replace. Minor
defects can be repaired by sand papering.
 Check the stuffing box for erosion and corrosion. Repair by
lapping if flaw is not too deep.
 Check, guide sections of body and disc for erosion and corrosion.
 Check bonnet bolts, hinge bolts and nuts for erosion, corrosion
and elongation of screw pitch. Replace if deformed.
 Replace gasket and gland packing.
 Check the gap of fitted in parts for wear and cracks.

13 WATER LEVEL INDICATORS

Operational Checks:

 Check to see if the gauge or indicator is showing the proper water

level. On water gauges this can be done by opening the drain
slightly, then quickly closing the drain to avoid damage to the
mica. Watch for the water level to return to its normal position.
 Check for water or steam leaks from ports or from the
connections to the drum. Leakage at the water column or drain
connection will cause a false water level in the gauge glass.
 Replace any burnt out indicator lights.
 Inspect glass for discoloration or fouling. If glass appears dirty
(fouled), blow down to clean it, remove it from service and
replace, install new glass if it is discolored, chipped. If for any
reason the glass and cushion gaskets are removed, replace them.
 Perform a wash down (cleaning) of gauge. Blow down the dirt leg
of remote level indicator to remove suspended matter from the
lines. Remove to to three cups only. Make sure to close
instrument valves first.

Every 6 months:
 Replace mica gasket and glass assembly.
 Perform a total rebuild as a preventative measure, since ports
tend to fail in succession. Follow proper torque tightening
procedure.

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 ISGEC John Thompson

Annually

 Inspect low and high level alarms (probes or floats) if provided .

 Check that all connecting piping to the column and glass is clear
and unobstructed.
 Repair any leaks of steam or water coming from piping or valves
observed during operation.

REFER MANUFACTURE MANUAL FOR DETAIL OVERHAUL

14 LONG RETRACTABLE SOOT BLOWERS

Operational Checks :

While doing a routine inspection of the boiler, inspect for condensate,

steam or oil leaks from the soot blowers.

Weekly:

During routine soot blowing, check and verify blowing pressures at

the header as well as critical locations such as upper heater and
economizer.

Monthly:

 Perform a visual inspection of blower at rest and during normal

operation to check for proper extension and retraction.
 Check for proper direction of rotation.
 Check the extended or blowing position of the nozzle or element to
ensure that it will give good cleaning results without damaging the
walls, cavity or lanes, which it is, designed to clean.
 Check the start and finish-blowing arcs on corner mounted
blowers and those, which are mounted adjacent to division walls,
etc., to ensure that the blowing medium is being directed in the
proper area for best cleaning results and to avoid damaging tubes.
 Check the wall-box sleeve alignment to boiler wall to ensure it is
perpendicular (plumb) with the vertical place of the wall in all
directions.
 Check for condensate or slag in wall-boxes. Condensate in a wall-
box can indicate a leaky puppet valve, while slag can reveal the
need for seal air.
 Ensure that the wall-box seal plate is free to float.
 Inspect wall-box and sleeve for damage. A damaged wall-box sleeve
can result in deteriorated wall-box and damaged boiler wall
refractory or insulation. This in turn can result in support
problems and casing leaks.

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 ISGEC John Thompson

 Ensure the proper operation of all moving and mechanical part.

 Check the condition of the expand cable.
 Inspect tubes in the vicinity of soot blower paths for possible metal
loss due to fly ash erosion, steam cutting, rubbing or soot-blowers
or corrosion.
 Check condition of the feed tube and valve stem packing. Replace
if hard and dry. Add more packing rings to the feed tube gland as
necessary. Do not over tighten.
 Check puppet valve valves condition. If the valve shows signs of
leakage, re-lap and inspect internals for corrosion or damage.
 Ensure the valve spring, spring retainer, yoke and trigger are
intact, and that the lance tube is not riding on the wallbox seal.
 Test forward limit switch actuator for proper spring action and
check for broken or distorted parts.
 Check front stop blocks for broken or cracked welds.
 Check for excessive rack wear at reversal point.
 Check for corrosion of front blower beam.
 Lubricate steam turn-on cam and linkage through fittings
provided.

 Check auxiliary lance and feed tube support for the following.

 Proper orientation of lance roller bracket

 Assembly
 Roller orientation.
 Distorted or bent trip fork
 Sheared trip fork stop pin
 Proper lubrication of rollers, trip linkage

 Lubricate front and rear hub bearings through fitting provided.

REFER MANUFACTURER MANUAL FOR DETAIL

15 ROTARY SOOT BLOWERS

Operational Checks:

While doing a routine inspection of the boiler, inspect for condensate,

steam of oil leaks from the blowers.

Weekly:

During routine soot blowing, check and verify blowing pressures at

the header as well as critical locations such as banks and economizer.

Monthly:

Perform a visual inspection of blowers at rest and during normal

operation, to ensure proper rotation and re-set.

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 ISGEC John Thompson

Check for proper direction of rotation.

Annually :

 Check the extended or blowing position of the nozzle or element to

ensure that it will good cleaning results without damaging the
walls, cavity or lanes, which it is, designed to clean.
 Check the start and finish blowing arcs of blowers to ensure that
blowing medium is being directed in the proper area for best
cleaning results and to avoid damaging tubes.
 Check the wall-box sleeve alignment to boiler wall to ensure it is
perpendicular (plumb) with the vertical plane of the wall in all
directions.
 Check for condensate or slag in wall-boxes. Condensate in a wall-
box can indicate a leaky puppet, valve, while slag can reveal the
need for seal air.
 Ensure that the wall-box seal plate is free to float.
 Inspect wall-box and sleeve for damage. A damaged wall-box sleeve
can result in deteriorated wall boxes and damaged boiler wall
refractory or insulation. This in turn can result in support
problems and casing leaks.
 Ensure the proper operation of all moving and mechanical parts.
Inspect for main bearing breakdown and worn-out drive pins
 Inspect tubes in the vicinity of soot blower paths for possible metal
loss due to fly ash erosion, steam cutting, rubbing or soot blowers
of corrosion.
 Check puppet valves condition. If the valve shows signs of leakage,
re-lap and inspect internal for corrosion or damage.
 Ensure the valve spring, spring retainer, yoke and trigger are
intact, and that the portion or the trigger the makes contact with
the valve stem does not show excessive wear.

 Inspect for the following on the cam and trigger.

 Excessive wear
 Distorted valve trigger. Restricting opening of the valve.
 Proper engagement and depression of the valve lift pin (located on
the large gear wheel) is intact and making contact with ear on the
valve trigger when the trigger rides off the cam.

 Lubricate the following areas :

 Worm gear housing

 Worm trust bearings

REFER MANUFACTURER MANUAL FOR DETAIL

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 ISGEC John Thompson

16 FANS

Operational Checks :

 Inspect bearing lubrication and check for proper oil level / grease.
 If ring-oiled, check for free revolution and adequately distributed
oil.
 Check bearing temperatures. If hot, determine cause and remedy
the situation. Oil temperature should not exceed 82 degrees
Celsius (180 degree Fahrenheit). White metal temperature should
not exceed 88 degrees C (190 degrees F).
 Ensure a flow of water is getting to the bearings and that the water
out temperature is not excessively warm of provided , if water
cooling is provided.
 Ensure that the seals are intact and functional.
 Feel the unusual motor or fan noises.
 Look for any loose material, which may get sucked into the fan.
 Visually inspect bearing seals.
 Lubricate drive assembly linkages.

Prior to Annual Shutdown:

 Take vibration readings.

 Check control room records of fan for.
 bearing vibration over the past few months
 bearing temperature over the past few months
 oil usage, if any
 check damper operation and indication.

Annually:

 Change bearing oil , grease. Analyze a sample from each bearing.

 Flush cooling water jackets it provided.
 Check motor-fan alignment.
 Inspect fan shaft seals for wear.
 Check foundation for cracking, sagging or any other deterioration
to concrete or steel works.
 Grease linkage connections.

FAN HOSING

 Check for sings of wear or corrosion ,damage .

 Check tightness of foundation bolts.
 Visually inspect for cracks

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 ISGEC John Thompson

INLET CONE

 Check for signs of wear or corrosion

 Damage
 Check clearance and fit up and ensure it is correct

ROTOR WHEEL

 Check for signs of corrosion

 Check for abrasive wears on blades.
 Check that the wheel is completely clean, and that the blades and
the should are free of any build up.
 Check that the wheel is tight on the shaft.
 Check that the shaft is straight
 Check for mechanical damage indicating an object has entered
the wheel during operation .
 Visually inspect for weld cracks, if in doubt, perform a liquid dye
penetrate test.

ROLLER BEARINGS
 Clean bearings, take oil grease sample.
 Disassemble, clean and check clearance between rollers and the
inside diameter of the bearing outer ring.
 Inspect the seals.
 Check bearing gaps in housing.
 Inspect rollers for flat spots.
 Check bearing hold-down bolts for tightness.
 Clean top and bottom half of bearing housing split line
 Apply new sealant, reassemble and re-torque bolts.

SLEEVE BEARINGS
 Drain bearings, take oil sample.
 Disassemble and clean bearings.
 Inspect bearing liners for wear and condition, take pinch test if
needed.
 Inspect oil seals.
 Check screw tightness on oil rings.
 Check bearing thrust pad gaps and liner alignment.
 Check bearing hold-down bolts for tightness.
 Reassemble bearings and re-torque bolts.
 Re-torque plunger screw.
 Check cooling water flow is clear, if provided.
 Check all instrumentation operations.

LUBE OIL SETS

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 ISGEC John Thompson

 Take oil samples from all units.

 Clean unit, replace oil and filters.
 Check pressure and flow settings.
 Inspect all hoses and pipes for leaks.
 Check instrumentation and standby pump operation.
COUPLING
 Clean and inspect for internal wear.
 Renew all worn sealing devices.
 Renew all lubricants.
 Re-torque all bolts.
 Check for proper gap setting.
 Check alignment and realign if required.
DRIVE MOTOR AND BELTS
 Check condition of belt for cracks and wear.
 Check belts tension, and ensure they are a matched set.
 Inspect belt sheaves.
 Check motor hold-down bolts for tightness lubricate motor.
SHAFT SEALS
 Disassemble and check for wear.
 Inspect rotor shaft for wear in seal area.
SILENCERS (if applicable)
 Visually inspect for loose material.
 Check condition of screens.

REFER MANUFACTURER MANUAL FOR DETAIL

Section # 15 Page 19 of 19