Daily Checks

7.4.1 Daily walk-down checks in the boiler gives a good feel about the boiler
performance and health of the boiler to the shift in-charge and the
operators. The main components of walk-down check are visual,
sound, feel, control room data and local gauges. This information will
help to understand the performance of the equipment and take any
action required to improve or sustain its performance.
7.4.2 Walk-down starts from the boiler control room. Note the load on the
boiler, all other major parameters which you would like to have with
you while going around, the vibration levels of rotating equipment.
7.4.3 Make sure that the walk-down is taken up only when the load is
steady and not when transient. During transient and fluctuations of
load you may have need to look at certain specific parameter and
behavior to look at. This will be a list from your daily walk-down and
control room data.
7.4.4 After noting down the details from control room it will be a good idea
to go to the top floor of the boiler and start the walk-down from there.
Normally drum floor is the top most floors.
OPERATION AND MAINTENANCE MANUAL FOR 80TPH AFBC BOILER
AVANT-GARDE 7.4 KCP
7.4.5 It will be a good practice to just look for any deviation from the regular
appearance, like any hanger rod bent, any ash puff at any location,
the rocker arm position, etc. Also carefully watch and listen for any
steam leak noise.
7.4.6 Coming down to drum area look for
- Leakage of steam from any valves
- Leakage of steam from the drum man hole gasket – if yes this need
immediate shutdown of boiler and attending. This is a very rare
occurrence but has taken place.
- Look at the local water level gauge level indicated simultaneously
verifying with the control room reading used for drum level control.
Note any large variations for corrective action.
- Check the safety valves for any leak or abnormality.
- Look at the expansion guides at the drum floor for any
abnormality.
- Look at the corner connections of the buckstays / furnace rap
7.4.7 Watch and listen for any abnormal noise or steam leak noise at each
location.
7.4.8 Open the first peep hole from top available and watch for flame licking
or high deposit on the tubes. Also look for any black particles on the
ash deposited on the peep hole frame inside portion.
OPERATION AND MAINTENANCE MANUAL FOR 80TPH AFBC BOILER
AVANT-GARDE 7.5 KCP
- Note: Opening peep hole while boiler is under operation must be
done carefully. Be on the door side of the peep hole and slowly
open to see any positive pressure inside the furnace. Wait for a
second or two to be sure of absence of furnace puffing. Never put
your head and eyes too close to the peep hole. Always hold the
door handle as you can close the door if you suspect any furnace
pressurization.
7.4.9 Each floor as you are coming down go round the furnace and note
each corner connections, the valves for any leaks, any abnormal
sound, any vibration, the flame condition and fluctuations, the
deposition on walls and panels, the carbon particles on the peephole
inside, note also if any bridging of the opening with slag note also if it
is flowing or solid, look for any expansion restraint in each area.
7.4.10 It will be a good practice to carry few small bags and a scoop to collect
the carbon particles seen and any deposit noticed. Care must be
taken not to hurt you as these will be at a much higher temperature.
7.4.11 When you are in the burner / feeder floor look at the various damper
positions and correlate with the control room data and flame
condition. Look for any oil leak in the start-up oil burners. Look for
any ash leak from any area as you are coming down and note this
location.
7.4.12 After reaching the ground level look at the bottom ash for large
clinkers, un-burnt carbon, and watch the quantity too.