Boiler inspection practices

Boiler inspection practices

Daily inspection aspects of
Daily inspection aspects of
AFBC boilers
AFBC boilers
Check for deviations in Feedwater & boiler water
quality.
Check the condensate return conductivity is normal.
Check condensate pH does not deviate from 8 to
8.5. If the condensate pH is likely to be upset plan
for a separate storage tank.
Look for iron oxide contamination in condensate
return. In case of deviation take remedial action.
Check the DM water tank water pH is 8 to 8.5.
WATER QUALITY
WATER QUALITY
Check saturated steam conductivity remains normal
as before.
Check raw water turbidity due to rain and modify
the back washing cycle of filters.
Check appropriate PO4 levels are maintained as per
the boiler operating procedure.
When there is a possibility of boiler stoppages,
give blow down at all bottom most drains.
Do not practice intermittent blow down as it upsets
the chemical concentrations.
WATER QUALITY
WATER QUALITY
Blow down water shall not be reddish / whitish.
Reddish implies corroding boiler. Whitish water shows
excess chemical dosage. Ensure minimum hydrazine
levels are maintained as per water quality
recommendations.
Whenever feedwater pH becomes lower than 7, trip
the boiler and safeguard the boiler from low hydrogen
damage.
WATER QUALITY
WATER QUALITY
Check the temperatures of FD fan Plummer blocks
are normal. If abnormal, record in logbook for
change during shut down.
Keep the FD fan Plummer blocks clear from dust
accumulations. Every shift the dust shall be cleared
off the Plummer block.
FD SYSTEM
FD SYSTEM
Check the fan inlet wire screen is free
from blockage. The wire screen gets
blocked due to rope, waste paper, etc.
Check motor body temperature is normal.
If overheating is observed notify electrical
personnel.
FD SYSTEM
FD SYSTEM
Check the power cylinder is free from dust
accumulations.
FD FAN POWER CYLINDER
FD FAN POWER CYLINDER
Check the air heater gas outlet
temperature and air outlet temperatures
are normal. Use these values to identify
airheater tube failures.
Check O2 values before & after APH on
gas side. If there is increase in O2 after
APH, the APH needs inspection.
AIRHEATER
AIRHEATER
Check the Airbox is free from bed
material. The compartment drain valve
shall be operated with FD fan on.
Check bed temperature thermowell cooling
air is 0.1 kg/cm2.
Check compartment air operated power
cylinders are in normal working condition.
AIRBOX
AIRBOX
Clean up the fuel feeders.
Check the feeder motor body temperature
is normal.
Check the oil level is geared motor is
normal. If any leakage is observed the seals
shall be changed.
Check the feeder bearing temperature is
normal.
Measure and record the feeder motor
current. Compare the present reading with
earlier reading.
FUEL FEEDING SYSTEM
FUEL FEEDING SYSTEM
Check the chain & sprockets of the feeder
are free from dust. Chain shall be
lubricated with light oil.
Check the VFDs of fuel feeders are not
overheated.
Check the VFD is free from dust. Dust
shall be removed using hand blower.
Check the fuel is of right size.
FUEL FEEDING SYSTEM
FUEL FEEDING SYSTEM
Check bunker top inspection doors are in
closed condition. Otherwise foreign material
could go inside.
Check the feeder rpms are normal. If
there is large variation there should a
reason such increase in moisture content /
ash % / Lower GCV. Otherwise check for
accumulations in feeder.
FUEL FEEDING SYSTEM
FUEL FEEDING SYSTEM
Check the damper openings are not disturbed.
Ensure the secondary air pressures are set as per
load requirement.
Check the manometers / draft gauges indicating
the pressure settings are in proper working
condition.
SECONDARY AIR SYSTEM
SECONDARY AIR SYSTEM
Check the damper openings are not disturbed.
Ensure the air pressure is normal.
Check the PA fan header pressure is normal.
Check the PA fan current is normal. PA fan current
increases when the mixing nozzle is worn out.
PRIMARY AIR SYSTEM
Check the thermocouples are working. If not
working, replace the thermocouples. Order for
spare thermocouples.
Check Airbox pressure and air flow are normal.
Check the bed height is normal and is at least
300 mmWC to avoid static burning and thus clinker
formation.
Check compensating cables of thermocouples are
free from possible damage, from hot bed material.
FURNACE
FURNACE
Check the bed material is free from stones,
clinker. Bed material as required for one charge
shall be kept on stock.
Always maintain a constant bed height. Before
draining bed material charge the same quantity in
the furnace. Drain the bed by opening the drain
gate partly but never fully. This is to ensure that
the bigger size particles are removed effectively.
Never keep any compartment under slumped
condition for long. It could lead to caustic gouging
in bed coil.
FURNACE
FURNACE
Check for abnormal bed temperatures in any
compartment. It implies clinker has formed in the
bed. It is advisable to drain the bed and replace to
remove clinker pieces. If not, the boiler has to be
shut to clean the bed. Running with clinkered bed
leads to localized bed coil erosion.
Cross check the O2 % with orsat apparatus once
in a week.
FURNACE
FURNACE
Check the glands of valves in the Deaerator &
feed water storage tank are free from leakages.
In the level station, check the signal connections
of I/P transmitter & positioner are proper.
In the pressure control station, check the signal
connections of I/P transmitter & positioner are
proper.
Look for damage in insulation. Repair the
damaged insulation.
DEAERATOR
DEAERATOR
Check the local level gauge levels are tallying with
the panel indication.
Observe the steam plume & adjust if required.
Use initial heating line to boost up the deaerator
outlet water temperature in case it is too low.
DEAERATOR
DEAERATOR
Check the current taken by the feed pump is
normal.
Check the lubrication to bearings is normal.
Change over to stand by pump every month to
ensure the next pump is operational. Do this on
fixed dates. Check cooling water flow is adequate
and temperature is normal.
Operate the drain of the suction strainer of the
feed pump.
FEED WATER SYSTEM
FEED WATER SYSTEM
Check the continuous blow down is open.
Operate the drain valves of bed coil headers
whenever the beds are slumped. This is to remove
the sludge / suspended matter that may settle
down in the headers over a period of operation.
The blow down shall be given when the boiler is
still under pressure.
Check the remote drum level indication is
matching with local direct water level gauges.
BOILER SYSTEM
BOILER SYSTEM
Check the water level gauge is working
satisfactorily. Remote level indications can be
verified only with direct water level gauge.
If water is running down the gauge glass check
for suspended impurities in boiler water. Use
antifoaming chemicals to control.
BOILER SYSTEM
BOILER SYSTEM
Make sure safety valve exhaust pipe is not
blocked by foreign material such as dead birds.
SAFETY VALVE
SAFETY VALVE
Check the spray control valve opening is not
abnormal.
SUPERHEATER SYSTEM
SUPERHEATER SYSTEM
Check the ESP field current is normal.
Check all heaters are functioning.
DUST COLLECTION SYSTEM
DUST COLLECTION SYSTEM
FUEL HANDLING SYSTEM
FUEL HANDLING SYSTEM
Check crusher hammer condition & replace on
time schedule. Worn out hammers produce oversize
particles and increase recycling load to screen.
Check oversize chute is not overflowing and
mixing up with right size fuel.
Use coarser coal during monsoon times.
Check conveyor belt condition periodically to avoid
major shut down.
Check and remove the screen blinding by ropes,
stones etc.
Replace the screen if found damaged.
Check the ash is being discharged from all ash
points.
Check the LOI in the ash remains normal.
Check the dense phase vessels are evacuating
ash from hoppers above. Abnormal ash
accumulations can damage the boiler.
ASH HANDLING SYSTEM
ASH HANDLING SYSTEM
Flush condensing pots occasionally to clear the
dirt trapped. Isolate the transmitters while
flushing.
INSTRUMENTS & CONTROL
INSTRUMENTS & CONTROL
If any control valve is hunting set right the PID
values.
Make sure the combustion control does not raise
the feeder rpm abnormally.
INSTRUMENTS & CONTROL
INSTRUMENTS & CONTROL