INSPECTION AND TEST PLAN
PERIODIC INSPECTION OF GROUP IV STEAM BOILER PLANTS
ACCORDING TO GERMAN "STEAM BOILER DEGREE (DAMPFKV)" AND TRD REGULATIONS
Description
Exterior Inspection (TRD505)
Internal Inspection (TRD 506)
Hydrostatic Testing (TRD 507)
Additional Tests (TRD 508)
Qualification of
Operator(s) (TRD 500)
Inspection Certificate/Report
(SEE //16, //17 OF DAMPEKV AND TRD 500, 505, 506, 507, 508)
Inspection Intervals/Frequency Inspection Type
1 year Test/Inspection by Inspector
 Witness Visual
3 years Test/Inspection by Inspector
 Witness Visual
9 years Test/Inspection by Inspector
 Witness Visual
Upon essential changes, outages, accidents Test/Inspection by Inspector
and repair works  Surface texture
 Visual inspection devices
 Surface crack detection
 Bulging measurements
 Ultrasonic testing
 Radiographic testing
 Strain measurements
 Material testing
 Chemical analysis of deposits
1 year Review
each inspection of partial inspection Report
Extent of Inspection
 Steam boiler
 Feedwater heaters
 Isolatable superheaters
 Reheaters
 Pressure expansion vessels
 Desuperheaters in boiler room
 Piping up to shut-off valves
 Fuel storage tanks
 Steam boiler
 Feedwater heaters
 Isolatable superheaters
 Reheaters
 Pressure expansion vessels
 Desuperheaters in boiler room
 Piping up to shut-off valves
 Fuel storage tanks
 Steam boiler
 Feedwater heaters
 Isolatable superheaters
 Isolatable reheaters
 Pressure expansion vessels
 Desuperheaters in boiler room
 Piping up to shut-off valves
where is necessary
acc. // 26 Damplk V
acc. // 22 DamplkV
 PERFORMANCE OF PERIODIC INSPECTION

EXTERIOR INSPECTION (TRD 505)

1. The condition of the plant shall be discussed by the inspector and the user

2. The conformance of the steam boiler plant with the statuary approval and the condition of the
plant shall generally verified according to the following points in which case the plant is to be
inspected by the inspector :
2.1. The assessment of the general condition of the plant namely :
 Boiler components
 Hot water expansion vessel (when accessible)
 Combustion chamber through inspection holes
 Boiler support structure and stays
 Brickwork
 Skin casing
 Thermal insulation
 Closures
 Inspection openings
 Detection of leakages
 Condensation water
 Discoloration
 Vibrations

 Firing and fuel handling, storage and treatment facilities

 Air pipes or ducts
 Air heaters
 Flue gas ducts
 Explosion doors
 Slag and ash removal plants
 Inadmissible deposits of pulverized fuel and wood dust

 Feed steam hot water discharge and drain lines

 Mufflers of the pressure relief devices

 Corrosion frost and fire protection installations

2.2 Safety-relevant equipment on the steam and water side.

 Water level pressure and temperature limiters with regard to their function
 Feed pumps: Readiness, change over operational readiness of stand-by pump
 Circulating pumps: Response of the warming system readiness change over
 Pressure relief devices: Set pressure, function, protection against international main
adjustment
 Pressure retaining devices with external pressure generation: Change-over points
 Non-return valves, shut-off and drain devices: Protection of body against inadmissible
overpressure
2.3. Safety-relevant firing equipment with regard to function
 Equipment on fuel tank
 Safety devices of fuel oil preheaters
 Fuel lines and equipment including valves
 Safety shut-off devices, check of tightness, and tightness control devices
 Feeding devices and burners
 Inspection holes for combustion chamber, burner lining and flame pattern
 Instruments measuring and indicating air pressure and amount of draught

2.4. Electrical safety circuit. Examination for possible defects

 Connecting contacts
 Wiring of monitoring and limiting devices
 Wire laying
 Operation conditions in conformance with design assumptions

2.5. Mode of operation

 Review of records on the feedwater and boiler water condition

2.6. Deformations of individual boiler parts

2.7. Operation
 Availability of operating instructions
 Familiarity Operator(s) with the operation of the plant

INTERNAL INSPECTION (TRD506)

Methods: Visual Inspection, Visual inspection devices, bulging determination, WT measurement,

surface crack detection

2.1. Walls of boiler drums

 Ligaments in tube arrays

 Edges and bearing of holes
 Tube nozzles
 Feedwater entry
 welded joints
 Welds for lugs and other parts and internal attachments of internals
 When necessary, surface crack detections shall be conducted
 Evaluation of deposits
 Tube penetrations and nozzles on boiler drums
 Suspensions, supports, manhole closures

2.2. Boiler shell and heads, furnaces, fireboxes, reversal chamber and similar componers
Where accesible VI on water and steam side of :
 Rivered, expanded, welded and bolted joints
 Knuckles, stays, tie rods and the like
 Nozzles
  Pipe connections, attachments and condition of internals
 Manhole closures and inspection openings
 Deposits shall be judged
 Flue gas and fireside walls and the external walls: furnaces, knuckles, nozzles, manhole
closures access openings, boiler saddles and supports.

2.3. Circular headers and threaded closures, rectangular headers, single headers, sectional headers,
stoker, cooling headers
Internal and external visual inspection where possible.
 Threaded closures
 Nozzles, welded joints
 Knuckles
 Tube arrays and rows
 Suspension, supports, spacers, expansion possibilities

2.4. Walls and tubes of the furnace

 Areas of burners, shoot blowers
 Inspection openings and other openings
 Transition area between protected and unprotected heating surface
 Buldging and displacement of tubes shall be evaluated
 Tube suspension and expansion possibilities shall be examined
 All parts of firing system and the explosion doors

2.5. Tube nests, interconnecting pipework and piping

Inspection of their external surface
 pipe bends and bifurcations
 Positioning of tube nests and their exterior coils
 Suspensions spacers, and expansion possibilities

2.6. Fittings and valves

External visual inspection
 Welded joints, extrusions, supensions, supports

Internal visual inspection

 Bodies of water level and limiting devices and blow down valves with NPS DN50

2.7. Flue-gas heated feedwater heaters

Visual inspection on the flue gas side
 Corrosion due to temperatures below dew point

2.8. Desuperheaters
Visual inspection on the surface
 Tubes, baffles, tube plates and ligaments, flanges and boits.

2.9. Pressure expansion vessels

Visual inspection on the water and steam side
2.10. Bolts of X22 Cr-MoV 121
Examination for surface cracks, ultrasonic examination

3. Hydrostatic testing

3.1. Hydrostatic testing for desuperheaters may be waived when the measures of paragraph 4.5 of
TRD 50 are taken.

3.2. Test gauge pressure

p= 1.3 x p1 for land and marine steam boilers and parts thereof.
P= 1.2 x P1 for land and rivercraft steam boilers solely consisting of seamless or welded drums,
headers and tubes and parts thereof.

3.3. Holding time

Half an hour. Water temperature max. 50oC.

3.4. Inspection of walls

No cracks, unacceptable deformation and leakage.