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Penyelenggaraan Pemeriksaan Dan Pembaikan Dandang
Penyelenggaraan Pemeriksaan Dan Pembaikan Dandang
2. Jenis-jenis Selenggara
Penyelenggaraan Pembetulan (corrective)
penyelenggaraan pencegahan (preventive)
penyelenggaraan ramalan (predictive)
4. Activities
Routine service (preventive)
Repair (corrective)
Inspection (preventive/predictive)
Overhaul (predictive)
5. After 5-6 months of the boiler operation, the boiler should be down for maintenance.
(1) To clean off the deposits in the drum, headers of the boiler
(2) To clean off the soot on the heating surface.
(3) Inspection on the internal or external sections of the boiler, such as check of the
welds of the pressure parts and steel sheets for corrosion. Severe defects shall be
subject to immediate remedy action. If the suspicious defects are located but not
impacting the safe operation, records shall be taken for future reference.
(4) Check the induced draft (ID) fan for bearing abnormality, check the impeller and the
casing for wears and tears. The user shall keep sufficient spare parts for the
impellers.
(5) Some portions of the boiler walls can be removed for thorough inspection, if
necessary. When the inspection locates the serious damage, the complete repair has
to be carried out before start up. All the findings from the inspection and the repairs
after the inspections shall be entered into the boiler safety technical logs.
(6) Preservation for the boiler out of service for a long time:
a. Water preservation:
fill up the boiler with the treated water, and then boil up the water to
remove the air. Fully close all the doors and openings. Or fill up the boiler
with the de mineralized water of high alkalinity to prevent the corrosion.
The chemicals added into the de mineralized water usually are NaOH
(2kg/mᶾ) or Na₃PO₄ (5 kg/mᶾ), and that added into the boiler water are
NaOH (5 kg/mᶾ) or Na₃PO₄ (15-20 kg/mᶾ). This method is only for short
time shutdown preservation with the heating surfaces and the boiler walls
properly dried.
b. Pressure preservation:
After removal of deposits from inside the boiler, all the valves shall be
closed. Preservation solution is to be added up to the lowest point of boiler
outlet header. Heat up the boiler to create a pressure of 0.1-0.2MPa, and
then hold the pressure for 2-3 hours. After pressure is dropped down, the
preservation solution should be used again to fill up the boiler, and then
keep the pressure of 0.2MPa by using a hydraulic way. The preservation
solution is composed of caustic soda (100mg/L), phosphorus pent oxide
(100mg/L), sodium sulfate (250mg/L). During the preservation period,
regular inspection for the proper concentration of the solution is required.
When the concentration of sodium sulfate is found to be lower than
50mg/L, more of that chemical shall be added to keep the specified
concentration.
c. Nitrogen preservation(omitted)
When the boiler is down for a quite long time, the nitrogen preservation
can be applied.
Draining of Condensate
a) Remove water in steam pipelines, its can lead to water hammer.
b) Steam and slug of water travel at a very high velocity hit any obstruction
downstream and can result in severe damage, for example:
7. Maintenance Inspection
Dimensional
Erosion, corrosion, abrasive wear, deformation changes due to stress, cavitation
Distortion
Abstructed expansion, overheating, unequal expansion, overstress
Cracks
Fatique, thermal stress, water hammer, improper welding, poor design
Deposits
incomplete combustion, rust deposits, dusty condition, upstream sootblowing and
etc
Blockage
Accumulation of scales, soot, foreign matter, damaged strainer
PEMERIKSAAN DANDANG (INSPECTION):
Who
Why What
Boiler
Inspection
How When
Where
PIC SB/UPV must notify inspector in writing, which may affect safety or strength
SB/UPV
Loss boiler water, melting of fusible plug and tube burst
When we DO
inspection
and notify
DOSH?
Qualified Qualified Who Will
DOSH Insurance Authorised
3rd party owner's Do
Inspector Inspector Inspector
inspector inspector Inspection?
What?
Destructive
Test (DT)
What?
Specimen of part of boiler
taken and tested to it's limit to
destruction
DT Method: Tensile, Bend,
Charpy, Hardness, Fatigue,
Creep, Metallography and
chemical analysis
Boiler Inspection
FMA 1967, (Notification, Certificate of fitness and inspection)1970
Regulation 13, 14 and 17
Furnace
Front wall tubes including area of burner Furnace floor area
Side wall tubes including peephole area Rear wall tubes including boiler nose area
Secondary Superheater & Reheater
Secondary superheater tubes Secondary reheater tubes Boiler roof
Screen tubes Manhole and sootblower area
Tubes
Cutting of tubes for inspection and rewelding
Replacing worn-out tubes
Valves and Fittings Feedwater control valve and its bypass High pressure dosing valves
All safety valves Isolating valves of burner inlet and outlet
MSV and its bypass Boiler and drum blowdown valves
Economizer
Interior tubes and headers (corrosion, oxygen pitting and scale) Cleanliness and security of vent and drain
Exterior tubes and headers (corrosion, erosion and deposits) connections valves
Soot blower (impingement and leakage) Exterior casing for leaks and tightness and doors
Feedwater Regulator
Check leaks, operability and cleanliness
Do not dismantle if operation satisfactory
Check connecting lines and mechanism for proper function
Burner throat refractory
Pit refractory
Refractory Slag build up on refractory
Missing Insulation on
Check extend expansion and headers and drum
contraction of pressure parts during
startup and shutdown
Furnace
Check header support hangers
always in tension. Looseness and Casing Burner wear by observe
indicate obstruction to free
expansion and contraction flame shape and
completeness of combustion
Burner
Ease of operation burner
vanes, indicate burner
PSV dissembled and check for
any surface discontinuity at seat
mechanism condition
PSV. If any discontinuity
Pressure
presence, remove it via lapping Safety
or changing faulty internal etc Valve
Assemble and do leak test using
method : pnuematic pop (PSV)
test/water leak test Check for change of pressure
Superheater drop through SH, indicating
Tubes to internal condition of
tubes
Check temperature differences over
two units at constant load. Indicate
deposits/ build up Economize
Check pressure drop over any part r and air Check steam quality,
of system at constant load,
indicating misplaced/ bypassed
pre-heater indicate condition of steam
baffle scrubbers and separators
Boiler
Check noises in drums.
Drums
Maybe caused by loose
connections of drum internal
piping