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Chapter 4

Preventive Maintenance

Prior to the start of actual work, the person responsible must perform a
safety check based on the above method statement.
He must also use his own judgment to make sure that the equipment and
the prevailing working conditions are safe.
During maintenance work, all personnel must follow the safe working
procedures detailed in the method statement.

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Chapter 4

4.2

Preventive Maintenance

Routine Maintenance
The purpose of routine maintenance is the implementation of the preventive
maintenance program on a day-to-day basis according to a planned and correctly
executed inspection.
The routine maintenance activities are very important; if they are properly
performed, they will enhance the boiler reliability.
Good routine maintenance activities are effective in cost reduction through the
minimization of equipment downtime.
Cleaning is an important and necessary maintenance activity to prevent the
ingress of foreign material. Other major points are as follows: (Summarized major
routine activities are shown in Table 4-1).

4.2.1 Preparation
a)

Parts, Tools and Equipment


It is important to prepare the necessary parts, tools and equipment
before starting the actual work.
Routine maintenance generally requires a standard mechanical
toolkit, consumables, cleaning materials etc.
Any shortages of these items will affect the maintenance activity
and may delay the schedule.
Personal Protective Equipment (PPE) is necessary for the boiler
maintainer, and it must be worn/used at all times.
Upon completion of the work, all tools and equipment must be
serviced and stored correctly to make sure of its availability for
further use.

b)

Documentation
Documentation is an important part of any maintenance duty.
Note all findings on a comprehensive log sheet, reporting all
aspects of the boiler observed during the routine inspection.
The data recorded in these documents will be useful in determining
the cause of equipment failure found during annual
outage/corrective maintenance work.
Any abnormalities must be immediately reported to the concerned
department/personnel for rectification and must be detailed in the
report.

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Chapter 4

Preventive Maintenance

4.2.2 Inspection and Maintenance


The routine inspection of the boiler contains the following residual risk
factors when the boiler is in operation.
The operator and maintainer should exercise extreme care while
inspecting the boiler components.
The Figure 5-1 shows the inspection areas of the boiler.
The safety precautions and the details of inspection to be done are
explained in the following paragraphs.

CAUTION
Extreme care must be taken while inspecting the hot boiler and
pipelines. Hands and clothing can be burned by contact with
boiler parts.

CAUTION
Extreme care must be exercised while inspecting the furnace
through inspection holes. The furnace may be over pressurized at
any time due to control failure or furnace explosion. Flue gas
from the inspection holes could blow on to the face of the
inspecting personnel, causing serious eye injuries and breathing
trouble.
The inspecting personnel must wear proper personal protective
equipment such as eye protector and breather during inspection.
The operator must be provided with proper training to handle
such events.

CAUTION
Care must be exercised during the event of a furnace over
pressurization when the atmosphere surrounding the furnace
could be laden with dust.
The operator or maintainer should not panic and should move to
a safe place, wash the face with plenty of clean water and later
seek proper medical treatment.
The operator or maintainer must be provided with proper training
to handle such events.

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CAUTION
Extreme care must be exercised while checking high pressure
steam leakage. Superheated steam is invisible and will cause
serious burn injuries.
Use proper tools, wear personal protective equipment and keep a
safe distance when performing the inspection.

CAUTION
Inspection of the boiler for suspected tube leakage must be done
with the utmost priority.
Make a quick decision to shutdown the boiler if tube leakage is
confirmed in the superheater, reheater or economizer
assemblies. Any delay will lead to more serious damage and
possibly multiple failures.

CAUTION
The safety valve can open momentarily without any prior sign.
While opening, the safety valve will make a loud noise and it may
lead to some accidents due to panic.

CAUTION
Any restrictions for the free expansion of the boiler must be
cleared without any delay. If the restriction remains, the high
mechanical stress caused to the pressure parts could lead to
their failure.

CAUTION
The sulfur contents in the coal should be within the contracted
design value (3.10% wt max.), because the excessive content of
sulfur will promote the corrosion rate of the pressure parts.

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Chapter 4

a)

Preventive Maintenance

Water Wall Tubes

CAUTION
Do not exceed the design pressure. If the operation
pressure exceeds the design pressure, check the
safety valve for leakage, confirm the operation data
and monitor the operation status continuously.
As the water wall tubes are not fully accessible during operation of
the boiler, monitoring of the water wall condition must be done by
comparison of plant operating records and current operating data.
High outlet gas temperature or high fuel consumption combined
with high outlet gas temperature indicates that the water wall tube
surfaces are dirty, adversely affecting the heat transfer.
Wall deslaggers must be operated periodically. While carrying out
a soot blowing operation, ensure proper functioning of the drain
trap in the system. This will avoid damage to the tubes due to
impingement of wet steam.
In order to ensure reliable / trouble free operation of the
supercritical boiler, stringent water quality control is required. All
Volatile Treatment (AVT) for plant startup period and Combined
Water Treatment (CWT) for normal plant operation must be
performed as required.
The furnace must be monitored for thermal expansion during
operation (Refer to Figure 2-30). Readings indicated by the
expansion trams provided at various locations at the corners and at
the boiler guides / stoppers are to be compared with the
manufacturers guidelines / operating records. Any deviation
noticed must be analyzed and any restriction of free movement
must be removed.
The furnace buckstays are to be inspected for integrity and missing
corner linkages. Missing linkage pins may lead to undesirable
water wall panel vibration; hence missing pins must be replaced at
the earliest opportunity.
The water wall outer surface must be inspected for any traces of
water or flue gas leakage/air ingress through the insulation. Water
leakage normally occurs through a pin hole or crack developed due
to failure of water wall tube welding. The source of the leakage
must be located immediately and the area cordoned off with safety
tags. To prevent possible sequential damage, the leakage must be
rectified at the earliest opportunity.

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The furnace must be checked for any abnormal noise from inside
the furnace. Presence of noise or furnace pressure fluctuations
combined with an increase in feed water flow indicates the
presence of a water wall tube leakage. To prevent possible
sequential damage, the leakage must be rectified at the earliest
opportunity.
The observation port doors provided on the furnace water walls
must be checked for tight closing. Any observation port door left
open leads to air ingress to the furnace and reduces the operating
efficiency of the boiler.
This also may lead to a safety hazard to the operators and
maintainers and the nearby equipment due to pressurization of
furnace. Any open observation port door must be moved to the
closed position.

Note
When performing hydraulic pressure test, you must use ASME
standard (Temperature of water is above 20oC 21oC).

b)

Superheaters
The superheaters are not accessible during operation. Hence
monitoring of the superheater condition must be by comparison of
plant running records and current operating data.
Low superheat steam temperature combined with high flue gas
temperature in that zone indicates that the superheater tubes are
fouled with ash and/or the flue gas passages between the tubes
are blocked.
Soot blowing must be initiated or the frequency of soot blowing
operation increased.
While carrying out soot blowing operation, ensure proper
functioning of the drain trap in the system. This will avoid damage
to the tubes due to impingement of wet steam.
The superheated steam and the flue gas temperatures are to be
monitored before and after soot blowing. The metal temperature
recorder must be watched frequently for any abnormality. Any
abnormal high metal temperature indicates that the steam flow
through the superheater bank is low due to partial or complete
blockage.
This condition may result in tube failure. It must be brought to the
notice of the shift supervisor to analyze the cause or to initiate
steps to stop the boiler.

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In order to ensure reliable / trouble free operation of the


supercritical boiler stringent water quality control is required. All
Volatile Treatment (AVT) for plant startup period and Combined
Water Treatment (CWT) for normal plant operation must be
preformed as required..
The superheater areas in the boiler are to be checked for any
abnormal noise. An abnormal noise in the vicinity of a superheater
indicates a possible superheater tube failure. A quick decision
must be made to shutdown and repair the superheater tube
leakage as any delay could lead to a much more serious failure.
A high superheated steam temperature indicates that the steam
flow through the bank is inadequate, which may be due to a
sudden decrease in the steam demand or a malfunctioning of the
de-superheater. This must be checked and compared with the
plant operating records. The spray water availability and proper
functioning of the spray control valve are also to be checked.

CAUTION
Do not exceed the design pressure. If the operation
pressure exceeds the design pressure, check the
safety valve for leakage, confirm the operation data
and monitor the operation status continuously.

c)

Reheaters
As the reheaters are not accessible during operation, monitoring of
the reheater condition must be by comparison of plant running
records and current operating data.
Low reheat steam temperature indicates that the reheater tubes
are fouled with ash and/or the flue gas passages between the
tubes are blocked.
Soot blowing must be initiated or the frequency increased. The
reheat steam temperature is to be monitored before and after soot
blowing.
While carrying out soot blowing operation, ensure proper
functioning of the drain trap in the system. This will avoid damage
to the tubes due to impingement of wet steam.
In order to ensure reliable / trouble free operation of the
supercritical boiler, stringent water quality control is required. All
Volatile Treatment (AVT) for plant startup period and Combined
Water Treatment (CWT) for normal plant operation must be
performed as required.

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The reheater area in the boiler must be checked for any abnormal
noise. An abnormal noise in the vicinity of reheater indicates a
possible reheater tube failure. A quick decision must be made to
shutdown and repair the reheater tube leakage as any delay could
lead to a much more serious failure.

CAUTION
Do not exceed the design pressure. If the operation
pressure exceeds the design pressure, check the
safety valve for leakage, confirm the operation data
and monitor the operation status continuously.

d)

Economizer
As the economizers are not accessible during operation,
monitoring of the economizer condition must be by comparison of
plant running records and current operating data.
Persistent low economizer feed water outlet temperature combined
with high economizer outlet flue gas temperature indicates that the
finned tubes of the economizer are dirty and/or the flue gas
passages between the tubes are blocked.
Soot blowing must be initiated or the frequency increased. The
economizer outlet flue gas and inlet and outlet feed water
temperature are to be monitored before and after soot blowing.
While carrying out soot blowing operation, ensure proper
functioning of the drain trap in the system. This will avoid damage
to the tubes due to impingement of wet steam.
In order to ensure reliable / trouble free operation of the
supercritical boiler stringent water quality control is required. All
Volatile Treatment (AVT) for plant startup period and Combined
Water Treatment (CWT) for normal plant operation must be
performed as required.
The economizer area must be checked for any abnormal noise. An
abnormal noise in the vicinity of the economizer combined with an
increase in feed water flow indicates a possible economizer tube
failure. A sudden drop in flue gas temperature in the economizer
area is also indicative of a tube puncture. A decision must be made
to shutdown and repair the economizer tube leakage as any delay
could lead to a more severe failure.

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Chapter 4

Preventive Maintenance

The ash hopper below the economizer has to be inspected for


proper evacuation of ash. Any accumulated ash, if not evacuated
for a long period will form clinkers, will hinder the evacuation
process and will promote building up of ash in the hopper. The
accumulated ash must be cleared at the earliest opportunity.

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Chapter 4

TABLE 4-1

No.

Major Check Item

Superheaters

Check Method

ROUTINE MAINTENANCE CHECKLIST

Check Reference

Action to be Taken
(if beyond acceptable limit)

Remarks

Recommended
Maintenance
Frequency

Plant
instruments

Temperature, fuel
consumption and
steaming conditions
normal

Carryout wall deslaggers operation.

As required

Boiler expansion

Visual and
expansion
measurements

As per predicted
movement

Check for and remove any obstruction to free


movement

Weekly

Furnace buckstay

Visual

No missing corner
link pins

Change the corner link pins

Weekly

Boiler stoppers

Visual

Free movement

Remove any restriction to free movement

Weekly

Water or steam
leakage

Visual

No leakage

Repair leakage during unit outage

Every shift

Abnormal noise

Audible

No abnormal noise

Shut down and repair leakage

Every shift

Flue gas or fly ash


leakage

Visual

No leakage

Repair leakage during unit outage

Every shift

Water wall tubes High furnace


temperature with
high fuel
consumption and
sluggish steaming

MM-M01.01

Rev.004

Description

Preventive Maintenance

surface

instruments

High flue gas and low Carryout soot blowing operation


superheat steam
temperature

Abnormal noise

Audible

No abnormal noise

Fouling on the tube Plant

Shutdown and repair tube leakage

Every shift

Every shift

and vibration

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Chapter 4

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Continued from previous page


TABLE 4-1

No.

Tube surface
fouling

Plant
instruments

High flue gas and low Carryout soot blowing operation


reheat steam
temperature

Every shift

Abnormal noise
and vibration

Audible

No abnormal noise

Every shift

Fouling on the
finned tube
surface

Plant
instruments

High flue gas and low Carryout soot blowing operation


economizer outlet
feed water
temperature

Every shift

Abnormal noise
and vibration

Audible

No abnormal noise

Shutdown and repair tube leakage

Every shift

Steam leakage,
Boiler Safety
Valves and other simmering
boiler attached
valves

Visual

No steam leakage
visible and no
simmering sound
audible

Please refer to Safety Valve Manual.

Every shift

Boiler skin
casing

Visual

No gas leakage

Repair skin casing leakage

Economizer

Gas leakage

Shutdown and repair tube leakage

Remarks

Recommended
Maintenance
Frequency

Check Method

Reheaters

Check Reference

Action to be Taken
(if beyond acceptable limit)

Major Check Item

Please refer to vendor manuals of other attached


valves.
As required

MM-M01.01

Rev.004

Description

ROUTINE MAINTENANCE CHECKLIST

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Chapter 4

4.3

Preventive Maintenance

Outage Maintenance
The purpose of outage maintenance is to perform a preventive maintenance
program on a yearly basis through a planned and correctly executed
maintenance work program accompanying necessary inspections.
The outage maintenance activities are very important to extend the service of
the Boiler and to improve the reliability.
Major activities related to outage maintenance are as follows: (A summary of
major activities for outage maintenance are shown in Table 4-2).

4.3.1

Preparation
a)

Parts, Tools and Equipment


It is important to prepare the necessary parts, tools and
equipment before starting the actual work.
Routine maintenance generally requires a standard mechanical
toolkit, consumables, cleaning materials etc.
Any shortages of these items will affect the maintenance activity
and may delay the schedule. Personal Protective Equipment
(PPE) is necessary for the maintainers and it must be used/worn
at all times.
Upon completion of work, all tools and equipment must be
serviced and stored correctly to make sure of their availability for
future use.
In addition, it will be necessary to identify and request the
provision of any spare part requirements.
A boiler outage will, in certain cases, require the use of material
handling equipment.
After the overhaul, return unused spare parts for correct storage
and the used spare parts are to be reordered.

b)

Documentation
Documentation is an important part of any maintenance duty.
Note all findings on a comprehensive log sheet, reporting all
aspects of the boiler observed during the outage inspection.
The data recorded in these documents will be useful in
determining the cause of boiler failure found during annual
outage/corrective maintenance work.

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Chapter 4

Preventive Maintenance

Any abnormalities must be immediately reported to the


concerned department/personnel for rectification and are to be
detailed in the report.
Keep records of information regarding spares and consumables
used. These records will be used for future reference and spare
parts replenishment.
On completion of outage maintenance work, monitor the boiler for
correct operation and maintenance data logging. This will help to
determine the correct intervals of preventive maintenance
activities to make sure of optimum plant availability. The correct
recording of findings during inspection will build a valuable
document for future reference.

4.3.2 Inspection and Maintenance

CAUTION
Prior to carrying out any outage inspection, make sure
that the boiler is shut down, cooled and all isolations
are in place.

CAUTION
When carrying out welding work make sure that the
welder has the required welding qualifications.

CAUTION
When you inspect the boiler, be careful not to drop
foreign matters into the tubes.

a)

Furnace Header and Water Wall Tubes


Refer to the Figure 5-1 for the various inspection areas.
The water wall tubes, the nozzle weld joints and the lug and
support plate weld joints are to be inspected for erosion,
corrosion, cracking or any damage that could have occurred
during operation. Especially, thickness survey at tube bend part
should be done.
Carry out inspections on external surfaces including visual
inspection and NDT.

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The hanger rods, supporting the top headers, are to be inspected


for any damage.
Inspect the furnace inlet/outlet headers, intermediate headers
and manifolds externally and internally for any corrosion or
damage and also for accumulation of sludge or debris.
Remove hard deposits by physical means.
Inspect the water wall surfaces of the furnace side for signs of
overheating and deformation. Analyze and rectify the causes of
tube overheating and deformation, if any.
Inspect the water wall tube surfaces around the wall deslaggers
openings for steam erosion. If erosion is obvious, a thickness
survey must be performed to decide the extent of damage before
changing the tube.
The header inspection nozzle caps should be removed for a
visual internal inspection of the headers and to remove any
accumulation of scale deposits or debris. These nozzle caps are
to be replaced following the procedure described in GENERAL
at the end of Section 5.4.1 (Page5-21).
Within a 1 to 3 year period, sample pieces of water wall tubes
from the furnace front, rear and side walls are to be removed for
internal examination.
Tube sampling location:
Refer to the Figure 4-3.
Front wall:

One meter length of the tube


7943.25mm towards left from the
centerline of the front wall panel, with
tube centre at an elevation of 35,100
mm)

Right and left side wall:

One meter length of the tube


22.25mm towards right from the
centerline of the side wall panel, with
tube centre at an elevation of 35,100
mm)

The samples are to be sectioned and subjected to the


examination as described in Section 5.5 (Sample Tube Removal).

Note
The above sampling is not applicable to superheater,
reheater and economizer tubes.

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Chapter 4

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Note
MHI recommends chemical cleaning of water wall tubes at
fixed intervals to remove any internal salt deposits.
Also control the water chemistry (water quality) strictly
during normal boiler operation.

b)

Water Separator and Water Separator Drain Tank


Refer to the Figure 5-1 for the various inspection areas.
Inspect the water separator and the water separator drain tank
internally for any erosion, corrosion, cracking or damage that
could have occurred during operation.
Inspect the vortex breaker in the water separator for any damage
or crack that could have occurred during operation.
Within a 10 year period, the shell plate weld joints of the water
separator and water separator drain tank are to be inspected for
cracks, corrosion or damage.
The junctions of horizontal and vertical joints are to be examined
critically.
Inspect the shell plate surfaces also for erosion or corrosion.
Inspections must include both visual inspection and NDT.

c)

Superheater Headers, Tubes and Desuperheaters


The superheater tubes and nozzle weld joints are to be inspected
for erosion, corrosion, cracking or damage that could have
occurred during operation. Inspections are to be done on external
surfaces and are to include visual inspection and NDT. Especially,
thickness survey at tube bend part should be done.
The header inspection nozzle caps should be removed for a
visual internal inspection of the headers and to clear any
accumulation of scale deposits or debris. These nozzle caps are
to be replaced following the procedure described in GENERAL
at the end of Section 5.4.1 (Page 5-21).
A radiographic test is to be performed, if oxidation scale is
apparent or suspected on a superheater tube.
The tube support lugs, rod spacers, stopper tubes and stopper
plates are to be inspected for damage and/or missing parts.

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The hanger tubes, girdling tubes and the spacer tubes are to be
checked for their integrity and the superheater banks are to be
inspected for proper alignment. The superheater tube external
surfaces are to be inspected for any deposit of ash.
Inspect the erosion protectors and the anti short pass plate
supports for any damage and the severity of erosion. Change the
severely eroded protectors / plates.
Inspect the superheaters for other possible erosion and provide
additional protectors if required.
Inspect the superheater tube external surfaces for any deposit of
ash and clean where necessary.
The inside of the desuperheater is to be visually inspected for
excessive wear, damage to the liner pipe, the water spray pipe
and the spray nozzles. The internal visual inspection is to be
performed using a fiberscope inserted through the desuperheater
inspection nozzles. Inspect the counterbore of positioning
/support bolt and fillet welding part by ultrasonic test. The
clearance between liner pipe and desuperheater body should be
checked to confirm that specified value is ensured. (1ry SH
DeSH: 17.05mm/2ry SH DeSH:14.4mm). The hanger rods
supporting the headers are to be inspected for any damage.
Inspection and Maintenance Procedure for Superheater
Tubes (including steam cooled spacer tubes and girdling
tubes)
Normal Inspection
Perform the radiographic test for the bend of tube loop bottom in
the pendant panels in order to detect deposit of exfoliated scales.
The detailed procedure is described below.
Removal of Exfoliated Scale Inside Superheater Tubes

Scale that forms at the internal surface of heating tubes is


likely to exfoliate from the tube wall when the boiler is
shutdown. If exfoliated scale accumulates in the tube bends,
it can cause stoppage of steam flow in the tube which in turn
may causes overheating and subsequent failure of the tube.
Therefore, it is important that the tube bends of the
superheater be checked to insure that such scale has not
accumulated.

Measuring point
The bends of the superheater tubes in the pendant
panels.

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Inspection method
Radiographic test (e.g. x-ray procedure).

Criteria for cleaning (Refer to Figure 4-1)


If 50% of the cross section of the tube is blocked by the
exfoliated scales, the tube should be cut and the
accumulation of scale should be removed.

Inspection interval
Every outage maintenance or every year.

Note
For several years after the new construction, it is
recommended that the radiographic test for all bend parts in
the pendant panels be performed if the boiler is
continuously operated over half a year in order to grasp the
individual characteristics of scale growth and exfoliation for
this boiler.
In case that construction schedule is so tight that RT for all
bend parts in pendant panels cannot be carried out, the
sampling at regular interval in boiler width direction may be
applied.
If one or more tube of which more than 50% of cross section
is blocked by the exfoliated scales is found, the
radiographic test for all bend parts in the pendant panels
should be carried out without fail, and the tube should be
cut and the accumulation of scale should be removed.

FIGURE 4-1 CRITERIA FOR CLEANING OF SUPERHEATER TUBE

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Chapter 4

d)

Preventive Maintenance

Reheater Headers, Tubes and Desuperheaters


Refer to the Figure 5-1 for the various inspection areas.
The 1RY and 2RYreheater tubes and nozzle weld joints are to be
inspected for erosion, corrosion, cracking or damage that could
have occurred during operation. Inspections are to be done on
external surfaces and are to include visual inspection and NDT.
Especially, thickness survey at tube bend part should be done.
The header inspection nozzle caps are to be removed for a visual
internal inspection of the headers and also for the removal of any
accumulation of scale deposits or debris. After completing the
inspection and the removal of debris, the header caps are to be
replaced following the procedure described in GENERAL at the
end of Section 5.4.1 (Page 5-21).
The tube support lugs, rod spacers and support plates are to be
inspected for heat damage and/or missing parts.
The hanger tubes and spacer tubes are to be checked for their
integrity and the reheater banks are to be inspected for proper
alignment.
The reheater tube external surfaces are to be inspected for any
deposit of ash and cleaned.
Inspect the erosion protectors on the reheater tubes and the
installed anti short pass plate supports for any damage and the
severity of erosion.
Change the severely eroded protectors/plates. Inspect the
reheaters for other erosion and provide additional protectors if
required.
The inside of the desuperheater is to be visually inspected for
excessive wear, damage to the liner pipe, the water spray pipe
and the spray nozzles. The internal visual inspection is to be
performed using a fiberscope inserted through the desuperheater
inspection nozzles. Inspect the counterbore of positioning
/support bolt and fillet welding part by ultrasonic test. The
clearance between liner pipe and desuperheater body should be
checked to confirm that specified value is ensured. (RH DeSH:
15mm)
The hanger rods supporting the headers are to be inspected for
any damage.

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Inspection and Maintenance Procedure for Reheater Tubes


Normal Inspection
Perform the radiographic test for the bend of tube loop bottom in
the pendant panels in order to detect deposit of exfoliated scales.
The detailed procedure is described below.
Removal of Exfoliated Scale Inside Reheater Tubes

Scale that forms at the internal surface of heating tubes is


likely to exfoliate from the tube wall when the boiler is
shutdown. If exfoliated scale accumulates in the tube bends,
it can cause stoppage of steam flow in the tube which in turn
may causes overheating and subsequent failure of the tube.
Therefore, it is important that the tube bends of the reheater
be checked to insure that such scale has not accumulated.

Measuring point
The bends of the reheater tubes in the pendant
panels.

Inspection method
Radiographic test (e.g. x-ray procedure).

Criteria for cleaning (Refer to Figure 1)


If 50% of the cross section of the tube is blocked by the
exfoliated scales, the tube should be cut and the
accumulation of scale should be removed.

Inspection interval
Every outage maintenance or every year.

Note
For several years after the new construction, it is
recommended that the radiographic test for all bend parts in
the pendant panels be performed if the boiler is
continuously operated over half a year in order to grasp the
individual characteristics of scale growth and exfoliation for
this boiler.
In case that construction schedule is so tight that RT for all
bend parts in pendant panels cannot be carried out, the
sampling at regular interval in boiler width direction may be
applied.

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Chapter 4

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If one or more tube of which more than 50% of cross


section is blocked by the exfoliated scales is found, the
radiographic test for all bend parts in the pendant
panels should be carried out without fail, and the tube
should be cut and the accumulation of scale should be
removed.

FIGURE 4-2

e)

CRITERIA FOR CLEANING - REHEATER TUBE

Economizer Headers and Tubes


The economizer tubes, hanger tubes and nozzle weld joints are
to be inspected for erosion, corrosion, cracking or damage that
could have occurred during operation. Inspections are to be done
on external surfaces and are to include visual inspection and
NDT. Especially, thickness survey at tube bend part should be
done.
The header inspection nozzle caps are to be removed for a visual
internal inspection of the headers and also to clear any
accumulation of sludge or debris.
After completing the inspection and the removal of debris, the
header caps are to be replaced following the procedure
described in GENERAL at the end of Section 5.4.1 (Page 5-21).
The tube spacers, fins and supports are to be inspected for
damage and/or missing parts.
Selected nozzle weld joints and tube joints are to be subjected to
a visual inspection and NDT.
Inspect the erosion protectors on the economizer tubes and the
installed anti short pass plate supports for any damage and the
severity of erosion.

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Change the severely eroded protectors.


The economizer tube fins are to be inspected for deposits of ash
and cleaned as necessary.

f)

Pipe Supports
The pipe supports on high pressure/high temperature pipe work
must be inspected during major outages or surveys.
Install a scaffolding to assure safety.
At first check the actual condition of the hanger assembly,
and then check the dynamic functioning of the spring unit.
Perform a thorough visual inspection of all elements of the
hanger to find the damage due to corrosion, wear or abuse.
This must also include the fixing of additional members to the
building steel work.
Make sure that the spring is intact and lubricated recently.
Also make sure that the hanger rod is normally straight and
vertically aligned.
Visually check the moving parts for telltale marks in the
grease or as bright metal to make sure that the component
has been functioning.
Check the position of the lever arm for the spring
compression plate to see if the support is within its functional
travel range or it is strained by the travel limiters. When
inspecting springs, check that the space between the coils
will allow further compression to occur.
General inspection of the pipe work is also necessary.

g)

Seal Plate with Refractory


Cr-Mo material (SA387-22-1) is used for the seal plate for boiler
bottom furnace. The seal plate is consider as a wear-out part, it
must be inspected in regular basis. If there is any wear-out to the
seal plate, repair with equivalent plate or by welding.
Measure the thickness of the seal plate during maintenance. If
the thickness of seal plate is 2mm or more, it is acceptable to
repair by welding. However, if the thickness of seal plate is 2mm
or less, please repair with equivalent plate.
The DCC seal plate is installed to prevent the escape of the
furnace gas and to absorb the thermal expansion of the boiler.

Boiler
Mitsubishi

4-23

Chapter 4

Preventive Maintenance

Seal plates are provided with stiffeners. Castable refractory and


insulation is provided on the seal plate as protection against
furnace heat radiation. It is possible that the refractory can be
damaged by the falling clinker. In that case the temperature of
seal plate may increase requiring a cooling fan to cool the hot
spot. Seal plate material used is SUS410, which can withstand a
temperature approximately 700C. In case of any damage to the
refractory due to clinker falling, it does not affect structurally the
seal plate.
During maintenance of the DCC any damaged parts of the
refractory / insulation are to be replaced. Refer to Figure 4-3.

CAUTION
It is possible that large size clinkers are formed in the furnace and
they fall into the DCC. Hence be careful of flooding while
inspecting DCC.
Create a restricted area and put safety signs during normal
operation.

Boiler
Mitsubishi

4-24

Chapter 4

Preventive Maintenance

BOILER-FRONT
C.L. OF Furnace

Clinker

Furnace bottom
membrane wall

Castable
refractory
Seal plate
Material SUS410

Buckstay
Cooling the
hot spot

Insulation
Stiffener
Support

Drip plate
MATERIAL

SA387-22-1

MPTD-4-333
MPTD-4-0333

MTD-4-0333

FIGURE 4-3

Boiler
Mitsubishi

DAMAGE TO REFRACTORY & CASTABLE BY FALLING CLINKER

4-25

Chapter 4

TABLE 4-2

No.

Water wall
tubes

Major Check Item

OUTAGE MAINTENANCE CHECKLIST

Check
Reference

Action to be
Taken
(if beyond
acceptable limit)
Repair or change

Nozzle weld joint

Dye
penetration
test, Visual

No cracks

Deposits and
thickness survey on
tube samples

Visual

No deposits

Carryout boiler acid


cleaning.

Measurement

Tube thickness
within limits

Repair or change
damaged tubes.

Deposit of clinker or
slag

Visual

No deposit

Remove manually
or by water
washing

Tube overheating

Visual

No overheating

Change damaged
tubes

Thickness survey at
tube bend part

Ultrasonic Test

Tube thickness
within limits

Repair or change
damaged tubes

Erosion, corrosion
or deformation

Visual

No erosion,
corrosion or
deformation

Repair or change

Furnace inlet
and
intermediate
headers

Corrosion,
accumulation of
debris

Removal of
inspection
nipple and
checking of
internal
surface

No corrosion or
deformation

Clear debris

Water separator

Erosion,
corrosion ,weld
cracks and damage

Dye
penetration
test, Visual

No cracks or
damage

Repair

MM-M01.01

Rev.004

Description

Check
Method

Boiler
Mitsubishi

Preventive Maintenance

Remarks

Inspection Date

Inspector

Results

Refer to Table
3-2 for details of
minimum tube
thickness

Inspection
nipples to be
restored after
inspection

4-26

Chapter 4

Preventive Maintenance

Continued from previous page


TABLE 4-2

OUTAGE MAINTENANCE CHECKLIST


Action to be Taken
(if beyond acceptable
limit)
Repair

Description

Major Check Item

Check
Method

Check
Reference

Water separator
drain tank

Erosion,
corrosion ,weld
cracks and damage

Dye
penetration
test, Visual

No cracks or
damage

Superheater
headers, tubes

Corrosion,
accumulation of
debris

Removal of
inspection
nipple and
checking of
internal
surface

No corrosion or
deformation

Clear debris

Thickness survey at
tube bend part

Ultrasonic Test

Tube thickness
within limits

Repair or change
damaged tubes

Weld cracks,
element
deformation, or
damage

Dye
penetration
test, Visual

No defective
parts

Repair or change

Ultrasonic test
and tube
thickness
measurement

Thickness of
tube within
limits

Spacer tube,
Girdling tube, rod
spacers, support
plates and stoppers

Integrity and
alignment

No damage, or
misalignment

Rectify misalignment

Tube protectors
and the anti short
pass plate supports

Erosion

No excessive
erosion

Replace protectors/plates

Nozzle weld joints

Dye
penetration
test

No cracks

Repair

MM-M01.01

Rev.004

No.

Boiler
Mitsubishi

Remarks

Inspection Date

Inspector

Results

Inspection
nipples to be
restored after
inspection

Refer to tables
3-7 to 3-9 for
details of
minimum
thickness

10year survey

4-27

Chapter 4

Preventive Maintenance

Continued from previous page


TABLE 4-2
Check
Method

OUTAGE MAINTENANCE CHECKLIST

Check
Reference

Action to be
Taken
(if beyond
acceptable limit)
Clean manually

No.

Description

Major Check Item

5
(Cont)

Superheater
headers, tubes

Ash deposit on tube


surfaces

Visual

No deposit

Hanger Tube
alignment

Visual

No deviation

Correct the
deviation

Deposit of
exfoliated scales at
pendant panels

Radiographic
test

No deposit
(Blockage
rate< 50%)

Remove deposit

Liner, nozzle wear


or damage, or
leakage

Visual using
fiberscope
Ultrasonic test

No wear or
damage, or
leakage

Repair or change

Clearance between
liner

Visual using
fiber scope

No deviation

Correct the
deviation.

Weld cracks,
element
deformation or
damage

Dye
penetration
test, Visual

No defective
parts

Repair or change

Ultrasonic test
and tube
thickness
measurement

Tube
measurement
within limits

Ash deposit on tube


surfaces

Visual

No deposit

Clean manually

Tube protectors

Erosion

No excessive
erosion

Change protectors

Reheater
headers and
tubes

Rev.004

Desuperheater

MM-M01.01

and the anti short


pass plate supports

Boiler
Mitsubishi

Remarks

Inspection Date

Inspector

Results

Ash deposit on
tube surfaces

10 year survey

10 year survey

4-28

Chapter 4

Preventive Maintenance

Continued from previous page


TABLE 4-2
No.
7
(Cont)

MM-M01.01

Rev.004

Description
Reheater
headers and
tubes

Economizer
headers and
tubes

OUTAGE MAINTENANCE CHECKLIST


Action to be Taken
(if beyond acceptable
limit)
Repair or change
damaged tubes

Check
Method

Check
Reference

Thickness survey at
bend at tube bend
part

Ultrasonic Test

Tube thickness
within limits

Deposit of
exfoliated scales at
pendant panels

Radiographic
test

No deposit
(Blockage
rate< 50%)

Remove deposit

Weld cracks,
deformation or
damage

Dye
penetration
test, Visual

No defective
parts

Repair or change

Ultrasonic test
and thickness
measurement

Thickness
measurement
within limits

Thickness survey at
bend at tube bend
part

Ultrasonic Test

Tube thickness
within limits

Repair or change
damaged tubes

Hanger Tube
alignment

Visual

No deviation

Correct the deviation

Tube protectors
and anti short pass
plate supports

Erosion

No excessive
erosion

Replace the
protectors/plates

No damage,
steam cut

As per recommendation
in the manual for safety
valve

Major Check Item

Inspection Date

Inspector

Results

10 year survey
Refer to tables
3-13 & 3-14 for
minimum
thickness

Safety valves

Internals, Popup
and reset pressure
setting

10

Boiler skin
casing

Gas leakage

Visual

No gas
leakage

Repair skin casing


leakage

11

Seal plate

Wear-out of seal
plate

Visual and
measurement
of thickness

No worn-out of
plate

Repair with equivalent


plate or by welding.

Boiler
Mitsubishi

Remarks

4-29

Chapter 4
BO ILER FRONT

S EC ON DA RY PASS
S ID E WA LL O UT LET HDR.

S EC ON DA RY PASS
F RO NT W AL L OU TL ET HDR.

FRON T W ALL
O UT LE T HDR.
R OO F IN LE T HDR.
+6 4500

Preventive Maintenance

O UT LE T HDR.

F RON T W ALL
O UT LE T HDR.

R EAR WA LL HAN GER


O UT LE T HDR.

P AS SA GE SIDE
W AL L OU TL ET HDR.

S EC ON DA RY PASS
D IV IS IO N WA LL O UT LE T HDR.

S EC ON DARY PASS
R EA R WA LL O UT LE T HDR.

+6 4200
+63200
R OO F TUBE

+62 810

+6 3200

+63 200
R OO F TUBE

FZRX-1
(FZLX-1)

LEF T SIDE ONLY

F ZRX-2
(FZLX-2)

B OT H SIDE

KZRU-1
(KZLU-1)
FZFU-1

FZFU-2

FZFU-3

FZFU-4

F ZFU-5

FZFU-6

FZFU-7

FZFU-8

FZRU-1
(FZLU-1)

FZRU-2
(FZLU-2)

F ZRU-3
(FZLU-3)

FZRU-4
(FZLU-4)

+4 9700

KZRU-1
(KZLU-1)

KZRU-1
(KZLU-1)

KZRU-1
(KZLU-1)

+5 6300

P AS SA GE SIDE
W AL L IN LET HDR.
P ASSA GE S ID E WALL

F RO NT W AL L IN TE RMEDIATE
O UT LE T HDR.

F ZFD-1

T.V

FZRD-1
(FZLD-1)

F ZFD-2

F UR NA CE INT ER MEDIATE
H DR (SID E WALL)
F UR NA CE INT ER MEDIATE
H DR (F RO NT WALL)

FTFA-1

FTFJ-1

F TFJ-2

CL O F A.A

+3 9061

+39 061 CL O F A.A

CL O F A.A

+3 7733

+3 7733 CL O F A.A

FTFA-2

FTFJ-3

A .A P ORT

FTFA-3

FTFJ-4

FTFJ-5

FTRJ-2
(FTLJ-2)

F TRJ-3
(FTLJ-3)

FTRJ-4
(FTLJ-4)
+39061 C
L O F A.A
+37733 C
L O F A.A

F TFA-4

22.25

S EC ON DA RY P AS S SIDE
W AL L IN LET HDR.

CL O F BO ILER

A .A P ORT

FTRJ-1
(FTLJ-1)

SECONDARY PASS SIDE WALL

A .A P ORT

A .A P ORT

7943.25

+3 1391 C
L O F CO AL B URNERS
+3 0729 C
L O F OIL BU RNERS

+3 1391 CL O F CO AL B URNERS
+3 0729 CL O F OIL BU RNERS

+31 391 CL O F CO AL B URNERS


+30 729 CL O F OIL BU RNERS

+3 0067 C
L O F CO AL B URNERS

+3 0067 CL O F CO AL B URNERS

+30 067 CL O F CO AL B URNERS

B UR NER PANEL

B UR NE R PANEL
+2 6453 CL O F CO AL B URNERS
+2 5791 CL O F OIL BU RNERS
+2 5129 CL O F CO AL B URNERS

+2 6453 C
L O F CO AL B URNERS
+2 5791 C
L O F OIL BU RNERS
+2 5129 C
L O F CO AL B URNERS

+26 453 CL O F CO AL B URNERS


+25 791 CL O F OIL BU RNERS

CL O F FU RNACE

+25 129 CL O F CO AL B URNERS


7943.25

FTFN-1

F TFJ-7

FTFN-2

FTFJ-8

F TFN-3

F TFJ-9

FTFN-4

FTFJ-6

F TFJ-10
+2 1515 CL O F CO AL B URNERS
+2 0853 CL O F OIL BU RNERS

+2 1515 C
L O F CO AL B URNERS
+2 0853 C
L O F OIL BU RNERS
+2 0191 CL O F CO AL B URNERS

+21 515 CL O F CO AL B URNERS


+20 853 CL O F OIL BU RNERS

+3 5100

+20 191 CL O F CO AL B URNERS

+2 0191 CL O F CO AL B URNERS

FTRJ-5
F TLJ-5)

FTRJ-6
(FTLJ-6)

FTRJ-7
(FTL J-7)

FTRJ-8
(FTLJ-8)

CL O F BO ILER

DETAIL A

FTRW-1
(FTLW-1)
FTF W-1

FTFW-2

FTFW-3

FTF W-4

FTFW-5

FTFW-6

FTFW-7

FTRW-2
(FTLW-2)

FTRW-3
(FTLW-3)

FTRW-4
(FTLW-4)

F TF W-8

22.25
+1 2000
LEF T SIDE ONLY

R IG HT SID E ONLY

+71 33.3

C
L O F FU RNACE

+7133.3

DETAIL B
FRONT WALL TUBE
VIEW FROM BOILER FRONT

MM-M01.01

Rev.004

+3 5100

F RO NT W ALL IN LE T HDR.

S ID E WA LL INL ET HDR.

RIG HT SIDE WALL TUBE


ASS'Y NO. IN ( ) SHO WN LEFT SIDE WALL.

FIGURE 4-4
Boiler
Mitsubishi

IDENTIFICATION OF WATER WALL TUBE SAMPLE LOCATION


4-30

Chapter 5

Disassembly and Reassembly

C ha pte r

5 Disassembly and Reassembly


Disassembly and reassembly are the activities to be conducted when internal parts of
the equipment are required to be accessed. An important part of the activities is the
preparatory work. This should identify the manpower, spares and tools that may be
required during the maintenance work.
A shortfall of any of these may affect the schedule and the operational status of the
plant. The major steps associated with disassembly and reassembly is as follows:

5.1

Water Wall Tubes, Roof Tubes, Headers and Manifolds

CAUTION
Prior to carrying out any maintenance, make sure that the
boiler is shutdown, cooled and all isolations are in place.

a)

Preparation
If water wall tube inspection and repair becomes necessary, all associated
equipment shall be mechanically and electrically isolated and an
authorized clearance and permit to work (PTW) shall be in place prior to
the commencement of work. The following points are also to be
considered when preparing for disassembly and reassembly:
Collect all necessary drawings (assembly drawings, sectional
drawings, part details, etc.) and documents (log sheets, field record
book, etc.) prior to the start of work.
Prepare the lifting platforms/gondolas and lights inside furnace with
necessary handling facilities to clean, inspect and maintain the
various parts of the equipment.
Prepare necessary scaffolding and lights in the passage pass and the
2ry pass.

Boiler
Mitsubishi

5-1

Chapter 5

b)

Disassembly and Reassembly

Inspection and Repair


Refer to the Figures 5-2 to 5-10.
All data is to be recorded during furnace and water wall inspection and
replacement.
For access to the furnace and water wall inspections suitable lifting
platforms/gondolas, scaffolding, walkways and temporary lighting are to
be provided. The following inspections and rectification, and/or changes
are to be carried out:
1

Inspect the water wall tubes for any corrosion, cracking or damage
that has occurred during operation. Inspection is to be carried out
externally and will comprise visual inspection and NDT.

Inspect all furnace bottom inlet headers (front, rear and side) on lug
weld joints for cracking visually and by NDT and repair as necessary.
Remove the inlet header inspection nozzle caps and remove any
accumulation of sludge from inside of the headers and then perform
an internal inspection using a fiberscope.

Inspect all the orifices for deposits & cracks by radiography. Repair
the orifices / joints for any cracks. If felt necessary, arrange for acid
cleaning of the boiler for removal of deposits on the orifices. For acid
cleaning procedure contact MHI.

Inspect the furnace bottom tube corner seal plate weld joints for
cracking visually and by NDT and repair as necessary.

Inspect all burner panel tube seal fins for burn damage or missing fins
and repair/change as necessary.

Inspect all intermediate header (front, rear and side) lug weld joints for
cracking visually and by NDT and repair as necessary.

Inspect all furnace outlet header (front, rear and side) lug weld joints
for cracking visually and by NDT and repair as necessary.

Inspect the roof inlet and outlet header lug weld for cracking visually
and by NDT, and repair as necessary.

Remove the passage pass and 2ry pass inlet header inspection
nozzle caps, and remove any accumulation of sludge from within the
headers and then perform an internal inspection using a fiberscope.

10 Inspect the passage pass and 2ry pass outlet header lug weld joints
for cracking visually and by NDT, and repair as necessary.
Boiler
Mitsubishi

5-2

Chapter 5

Disassembly and Reassembly

11 Remove all the manifold inspection nozzle caps, inspect and remove
any accumulation of sludge from inside of the manifolds and then
perform an internal inspection using a fiberscope.
12 Inspect the roof tubes for burn damaged or missing fins, and check for
flue gas leakage at the roof penetrations of superheater, reheater and
economizer tubes.
13 Inspect the refractory material in the area of the bottom tubes and
side wall tubes, roof tubes, nose section of rear wall and repair as
necessary.
14 Inspect the furnace access doors for signs of heat damage or flue gas
leakage. Check the block insulation and door seals and repair or
replace as necessary.
15 Reinstall all removed header and manifold inspection nozzle caps
following the procedure detailed in General in Page 5-7.

c)

Reassembly
1

Make sure that all lifting platforms, gondolas , scaffoldings, walkways


and associated equipment have been removed from the furnace and
flue gas passages and have been accounted for.

Note
Refer to Figure 5-1 for identification of inspection areas of the
boiler.
2

Close all access points to the furnace and flue gas passages.

5.1.1 Recommended 10 Year Inspection


It is a standard practice that insurers of power plant and some
governmental authorities insist on certain periodic statutory surveys
and inspections. Irrespective of these statutory requirements, it is
recommended that additional checks be carried out on selected items
within a 10 year period of operation.
The following inspections are applicable to the water wall tubes, its
associated pipes, headers and manifolds and are to be performed
during an arranged major outage.
Refer to the Figure 5-1 in which the inspection areas are indicated.
Record defect or deviation beyond the specified criteria, and change
and /or rectify as necessary.

Boiler
Mitsubishi

5-3

Chapter 5

Disassembly and Reassembly

Furnace Inlet Headers (Front , Rear and Side) (1-1)


1

Remove the header inspection nozzle caps and perform an


internal inspection of the headers using a fiberscope.

Visually inspect all nozzle weld joints for signs of cracking.

Perform dye penetrant test on 10% of the furnace wall tube


nozzles and on 20% of the supply pipe nozzles.

Perform radiographic inspection of all orifices in wall tubes for


signs of blockage or cracking.

Furnace Intermediate Headers (Front , Rear and Side ) (1-2)


1

Remove the header inspection nozzle caps and perform an


internal inspection of the headers using a fiberscope.

Visually inspect all nozzle weld joints for signs of cracking.

Perform a dye penetrant test on 10% of the furnace lower water


wall tube nozzles and 20% of the outlet pipe nozzles on the
furnace intermediate header.

Furnace 2nd Intermediate Headers (Front , Rear and Side) (1-3)


1

Remove the header inspection nozzle caps and perform internal


inspection of the headers using a fiberscope.

Visually inspect all nozzle weld joints for signs of cracking.

Perform a dye penetrant test on 20% of the 2nd intermediate


header inlet pipe nozzles and on 10% of the furnace upper water
wall tube nozzles.

Furnace Outlet Headers (Front , Rear and Side) (1-4)


1

Remove the header inspection nozzle caps and perform internal


inspection of the headers using a fiberscope.

Visually inspect all nozzle weld joints for signs of cracking.

Perform a dye penetrant test on 10% of the furnace upper water


wall tube nozzles and 20% of the outlet pipe nozzles.

Rear Wall Hanger Tube Inlet Header (1-5)


1

Boiler
Mitsubishi

Remove the header inspection nozzle caps and perform internal


inspection of the headers using a fiberscope.

5-4

Chapter 5

Disassembly and Reassembly

Visually inspect all nozzle weld joints for signs of cracking.

Perform dye penetrant test on 10% of the rear wall hanger tube
nozzles and on 20% of the inlet header supply pipe nozzles.

Rear Wall Hanger Tube Outlet Header (1-6)


1

Remove the header inspection nozzle caps and perform internal


inspection of the headers using a fiberscope.

Visually inspect all nozzle weld joints for signs of cracking.

Perform dye penetrant test on 10% of the rear wall hanger tube
nozzles and on 20% of the rear wall hanger outlet pipe nozzles.

Passage Side Inlet Header (1-7)


1

Remove the header inspection nozzle caps and perform internal


inspection of the headers using a fiberscope.

Visually inspect all nozzle weld joints for signs of cracking.

Perform dye penetrant test on 10% of the passage side wall tube
nozzles and on 20% of the passage side wall supply pipe
nozzles.

Passage Side Outlet Header (1-8)


1

Remove the header inspection nozzle caps and perform internal


inspection of the headers using a fiberscope.

Visually inspect all nozzle weld joints for signs of cracking.

Perform dye penetrant test on 10% of the passage side wall tube
nozzles and on 20% of the passage side wall outlet pipe nozzles.

Roof Inlet Header (1-9)


1

Remove the header inspection nozzle caps and perform internal


inspection of the headers using a fiberscope.

Visually inspect all nozzle weld joints for signs of cracking.

Perform dye penetrant test on 10% of the roof tube nozzles and
on 20% of the roof supply pipe nozzles.

Roof Outlet Header (1-10)

Boiler
Mitsubishi

Remove the header inspection nozzle caps and perform internal


inspection of the headers using a fiberscope.

Visually inspect all nozzle weld joints for signs of cracking.

5-5

Chapter 5

Disassembly and Reassembly

Perform dye penetrant test on 10% of the roof tube nozzles and
on 20% of the roof outlet pipe nozzles.

2ry Pass Inlet Header (Front, Rear, Side and Division) (1-11)
1

Remove the header inspection nozzle caps and perform internal


inspection of the headers using a fiberscope.

Visually inspect all nozzle weld joints for signs of cracking.

Perform dye penetrant test on 10% of the 2ry pass wall tube
nozzles and on 20% of the 2ry pass supply pipe nozzles.

2ry Pass Outlet Header (Front, Rear, Side and Division) (1-12)
1

Remove the header inspection nozzle caps and perform internal


inspection of the headers using a fiberscope.

Visually inspect all nozzle weld joints for signs of cracking.

Perform dye penetrant test on 10% of the 2ry pass wall tube
nozzles and on 20% of the 2ry pass outlet pipe nozzles.

Furnace Lower Water Wall Tubes (Front, Rear and Side) (1-13)
1

Visually inspect the outside surface of all water wall tubes for
signs of erosion, corrosion, deformation and cracks.

Perform ultrasonic test on tubes with signs of erosion, corrosion


or severe surface roughness.

Visually inspect the buckstay tie plate welds on the water wall
tube for cracks. Perform dye penetrant examination to check the
cracks.

Cut out a sample tube from the furnace front, side and rear walls
as indicated in the Figure 4-1.
The sample piece must be 1000mm in length and must be
removed, inspected and tested in accordance with Section 5.5.

Furnace Upper Water Wall Tubes (Front, Rear and Side) (1-14)

Boiler
Mitsubishi

Visually inspect the outside surface of all water wall tubes for
signs of erosion, corrosion, deformation and cracks.

Perform ultrasonic test on tubes with signs of erosion, corrosion


or severe surface roughness.

Visually inspect the buckstay tie plate welds on the water wall
tube for cracks. Perform dye penetrant examination to check the
cracks.

5-6

Chapter 5

Disassembly and Reassembly

Furnace Bottom Tubes (1-15)


1

Visually inspect the outside surface of all water wall tubes for
signs of erosion, corrosion, deformation and cracks.

Perform ultrasonic test on tubes with signs of erosion, corrosion


or severe surface roughness.

Visually and by NDT, inspect all tie plate weld joints for cracking.

Burner Panel Tubes (1-16)


1

Inspect all burner frame weld joints for signs of cracking, visually
and by NDT.

Roof Tubes (1-17)


1

Inspect the roof tube fins at the superheater and reheater tube
penetrations visually from the furnace side for burn damages or
missing fins.

Also inspect areas where damaged fins are found from within the
roof housing. Repair the damaged areas to prevent the leak of flue
gas from the furnace.

Passage and 2ry Pass Wall Tubes (1-18)


1

Visually inspect all the wall tube support plate weld joints and fin
tips for cracking.

Inspect all welds on the anti short pass plate supports.

Visually inspect all the wall tube fin ends at the bottom of the side
walls for cracking.

Visually inspect the buck stay tie plate welds on the back pass
wall tube for cracks. Perform a dye penetrant examination to
check for cracks in suspected areas.

GENERAL:
In locations where header inspection nozzle caps have been removed
to provide access for internal inspection of the header, weld
preparations are to be machined on the header nozzle and on the cap.
The cap is to be rewelded to the nozzle at a location approximately
10 mm from the original weld. Welds are to be subjected to NDT or
hydrostatic test.

Boiler
Mitsubishi

5-7

Chapter 5

Disassembly and Reassembly

Where sections of water wall tube have been removed for examination,
removal and change is to be done in accordance with the procedures in
Section 5.5. The areas from which the tubes were removed are to be
inspected after the stipulated hydrostatic test to confirm that scaffolding
and other equipment used have been removed.
Make sure that all scaffolding, walkways and associated equipment
has been removed from the furnace and flue gas passages, and have
all been accounted for.
Close up all access points to the furnace and flue gas passages.

Boiler
Mitsubishi

5-8

Chapter 5

5.2

Disassembly and Reassembly

Superheater Headers, Tubes and Desuperheaters

CAUTION
Prior to carrying out any maintenance, make sure that the
boiler is shutdown, cooled and all isolations are in place.

a)

Preparation
If superheater header, tubes and desuperheater inspection and repair
becomes necessary, all associated equipment shall be mechanically and
electrically isolated and an authorized clearance and work permit shall be
in place prior to the commencement of work. The following points are also
to be considered when preparing for disassembly and reassembly:
Collect all necessary drawings (assembly drawings, sectional
drawings, part details, etc.) and documents (log sheets, field record
book, etc.) prior to the start of work.
Prepare the lifting platforms/gondolas and lights inside furnace with
necessary handling facilities to clean, inspect and maintain the
various parts of the equipment.
Prepare necessary scaffolding and lights in the passage pass and the
2RY pass.

b)

Inspection and Repair


Refer to the Figures 5-15 to 5-20 & 5-25.
All data are to be recorded during the inspection and removal of
superheater headers, tubes and desuperheaters.
Access to the furnace and 2ry pass is required.
The following inspections are to be carried out.
The superheater headers, tubes and desuperheaters, in the areas shown
are to be inspected for any corrosion, cracking or damage that has
occurred during operation.
This inspection is to be carried out externally and should consist of both a
visual and an NDT inspection.

Note
Refer to Figure 5-1 for identification of inspection areas of the
boiler.
Boiler
Mitsubishi

5-9

Chapter 5

Disassembly and Reassembly

Inspect all 1ry, 2ry and 3ry superheater inlet and outlet header support
plate weld joints for cracking, visually and by NDT.

1ry Superheater Tubes (2-13)


1

Inspect the outside surface of all 1ry superheater tube panels


visually for signs of erosion, corrosion, deformation and cracks.
Perform ultrasonic thickness survey, where erosion, corrosion,
deformation or cracks are apparent, to confirm tube thickness.

Inspect all rod spacers, support plates for signs of burn damage or
missing spacers visually, and perform an NDT on those showing
burn damage or cracking. Inspect visually and perform an NDT on
all rod spacer weld joints for signs of cracking.

Visually inspect all seal collar weld joints at the roof penetrations
for signs of cracks or damage and perform an NDT on those
showing signs of damage.

Inspect visually all sleeve stopper weld joints of the hanger tubes
for signs of any burn damage and perform an NDT on those
showing signs of cracking.

2ry Superheater Tubes (2-14)


1

Inspect the outside surface of all 2ry superheater tube panels


visually for signs of erosion, corrosion, deformation and cracks.
Perform ultrasonic and dye penetrant test where erosion, corrosion,
deformation or cracks are apparent and on areas of missing or
deformed attachments. Perform ultrasonic test to confirm tube
thickness.

Inspect visually all support plates for signs of burn damage or


missing plates and perform an NDT on those showing burn
damage.

Inspect visually and perform an NDT on all rod spacer weld joints
for signs of cracking.

Visually inspect the girdling tube protector attachment welding and


perform an NDT on those showing signs of cracking.
Inspect the girdling tubes for signs of burn damage and change as
necessary.

Boiler
Mitsubishi

Visually inspect all sliding spacers for signs of burn damage or


missing sliding spacers and perform an NDT on those showing
burn damage.

5-10

Chapter 5

Disassembly and Reassembly

Visually inspect all seal collar weld joints at the roof penetrations
for signs of cracking and perform an NDT on those showing signs
of cracking.

3ry Superheater Tubes (2-15)


1

Inspect the outside surface of all 3ry superheater tube panels


visually for signs of erosion, corrosion, deformation and cracks.
Perform ultrasonic and dye penetrant test where erosion, corrosion,
deformation or cracks are apparent and on areas of missing or
deformed attachments. Perform ultrasonic test to confirm tube
thickness.

Perform radiographic test on the two most damaged panels if


oxidation scaling is suspected.

Inspect visually the various attachment welding and perform an


NDT on those showing signs of cracking.

Inspect visually all rod spacers, stopper tubes for burn damage or
missing members and then perform an NDT.

Inspect visually all support plate weld joints for signs of cracking
and then perform an NDT.

Inspect the girdling tubes for signs of deformation or burn damage


and change as necessary.

Visually inspect all spacer tube support lugs for burn damage and
missing lugs and then perform an NDT.

Visually inspect all seal collar weld joints at the roof penetrations
for signs of cracking and perform an NDT on those showing signs
of cracking.

Cooling Spacer Tube


Refer to Figure 2-18.

Boiler
Mitsubishi

Inspect visually the spacer tube for signs of bending or distortion.

Inspect visually all spacer weld joints for signs of cracking and burn
damage or missing spacers.

Inspect visually all spacer tube rod weld joints for signs of cracking
and then perform an NDT.

Inspect visually the tube sleeve weld joints for signs of cracking
and then perform an NDT.

5-11

Chapter 5

Disassembly and Reassembly

Girdling Tube
Refer to Figure 2-18.
1

Inspect visually the girdling tube for signs of bending or distortion.

Inspect visually all girdling weld joints for signs of cracking and
burn damaged, or missing spacers.

Inspect visually all girdling tube protector weld joints for signs of
cracking and then perform an NDT.

Inspect visually the tube sleeve weld joints for signs of cracking
and then perform an NDT.

Other areas
Inspect the furnace access doors for signs of heat damage or flue gas
leakage. Check the block insulation and door seals and repair or
change as necessary.

c)

Reassembly
1

In locations where header inspection nozzle caps have been removed


to provide access for internal inspection of the header, weld
preparations are to be machined on the header nozzle and on the cap.
The cap is to be rewelded to the nozzle at a location approximately
10mm from the original weld. Welds are to be subjected to NDT or
hydrostatic test.

Make sure that all scaffolding, walkways and associated equipment


has been removed from the furnace and flue gas passages, and all
have been accounted for.

Close up all access points to the furnace and flue gas passages.

5.2.1 Recommended 10 Year Inspection


It is a standard practice that insurers of power plant and some
governmental authorities insist on certain periodic statutory surveys
and inspection. Irrespective of these statutory requirements, it is
recommended that additional checks be performed on selected items
after a 10 year period of operation.
The following inspections are those applicable to the superheater
headers, tubes and desuperheaters and are to be performed at a
suitable time during an arranged major outage.

Boiler
Mitsubishi

5-12

Chapter 5

Disassembly and Reassembly

Note
Refer to Figure 5-1 for identification of inspection areas of
the boiler.

1ry Superheater Inlet Header (2-1)


1

Remove the header inspection nozzle caps and perform an


internal inspection of the header using a fiberscope.

Inspect visually all nozzle weld joints for signs of cracking.

Perform an NDT on 10% of the tube nozzles, all spacer tube


nozzles and on all inlet pipe nozzles.

1ry Superheater Outlet Headers (2-2)


1

Remove the header inspection nozzle caps and perform an


internal inspection using a fiberscope.

Inspect visually all nozzle weld joints for signs of cracking.

Perform NDT on 10% of the tube nozzles and on all outlet pipe
nozzles.

2ry Superheater Inlet Headers (2-3)


1

Remove the header inspection nozzle caps and perform an


internal inspection using a fiberscope.

Inspect visually all the nozzle weld joints for signs of cracking.

Perform NDT on 10% of the tube nozzles, all girdling tube


nozzles and on all inlet T-piece pipe nozzles.

2ry Superheater Outlet Headers (2-4)


1

Remove the header inspection nozzle caps and perform an


internal inspection using a fiberscope.

Inspect visually all nozzle weld joints for signs of cracking.

Perform NDT on 10% of the tube nozzles, all spacer tube nozzles
and on all outlet pipe nozzles.

3ry Superheater Inlet Headers (2-5)


1

Boiler
Mitsubishi

Remove the header inspection nozzle caps and perform an


internal inspection using a fiberscope.

5-13

Chapter 5

Disassembly and Reassembly

Inspect visually all the nozzle weld joints for signs of cracking.

Perform NDT inspection on 10% of the tube nozzles and on all


inlet T-piece pipe nozzles.

3ry Superheater Outlet Headers (2-6)


1

Remove the header inspection nozzle caps and perform an


internal inspection using a fiberscope.

2
3

Inspect visually all the nozzle weld joints for signs of cracking.
Perform NDT on 10% of the tube nozzles, girdling tube nozzles,
drain nozzles, all outlet pipe nozzles and nozzles provided for
instruments.

1ry Superheater Desuperheaters (2-7)


1

Remove the desuperheater inspection nozzle caps and using a


fiberscope inspect the inside of the desuperheater for excess
wear, damage to the liner pipe, the water spray pipe and the
spray nozzles.

After checking the inspection caps inspect the spray nozzle weld
joints for cracks using NDT.

2ry Superheater Desuperheaters (2-8)


1

Remove the desuperheater inspection nozzle caps and using a


fiberscope inspect the inside of the desuperheater for excess
wear, damage to the liner pipe, the water spray pipe and the
spray nozzles.

After checking the inspection caps inspect the spray nozzle weld
joints for cracks using NDT.
In locations where the header inspection nozzle caps have been
removed to provide access for internal inspection of the header,
weld preparations are to be machined on the header nozzle and
on the cap.
The cap is to be rewelded to the nozzle at a location
approximately 10 mm from the original weld. Welds are to be
subjected to NDT and/ or hydrostatic test as required by the local
regulations.
Make sure that all scaffolding, walkways and associated
equipment has been removed from the furnace and flue gas
passages, and all has been accounted for.
Close up all access points to the furnace and flue gas passages.

Boiler
Mitsubishi

5-14

Chapter 5

5.3

Disassembly and Reassembly

Reheater Headers, Tubes and Desuperheater

CAUTION
Prior to carrying out any maintenance, make sure that the
boiler is shutdown, cooled and all isolations are in place.

a)

Preparation
If reheater header and tube inspection and repair become necessary, all
associated equipment shall be mechanically and electrically isolated and
an authorized clearance and work permit shall be in place prior to the
commencement of work. The following points are also to be considered
when preparing for disassembly and reassembly:
Collect all necessary drawings (assembly drawings, sectional
drawings, part details, etc.) and documents (log sheets, field record
book, etc.) ready prior to the start of work.
Prepare the necessary handling facilities (e.g. suitable lifting
equipment, trolley and supports, etc.) to remove and store the various
parts of the equipment.

b)

Disassembly
Refer to Figure 5-21 to 5-24 & 5-26.
All data is to be recorded during the reheater headers and tubes
inspection and removal.
Access to the furnace is required with suitable scaffolding and walkways.

Note
Refer to Figure 5-1 for identification of inspection areas of the boiler.

Primary Reheater Inlet Header (3-1)


The primary reheater inlet header, which is located in the flue gas path
of the 2ry pass of the boiler, has to be inspected for any oxidation of
external surface material.
1

Remove the header inspection nozzle caps and using a fiberscope,


inspect the inside of the Reheater header for excess wear, damage
to the inlet pipe nozzles, the drain pipe and the reheater tube
nozzles. Remove the accumulated scale deposits.

In locations where the header inspection nozzle caps have been


removed to provide access for internal inspection of the header, weld
preparations are to be machined on the header nozzle and on the cap.
Boiler
Mitsubishi

5-15

Chapter 5

Disassembly and Reassembly

The cap is to be rewelded to the nozzle at a location approximately 10


mm from the original weld. Welds are to be subjected to NDT and/ or
hydrostatic test as required by the local regulations.
Ensure that all scaffolding, walkways and associated equipment has
been removed from the furnace and flue gas passages, and has all
been accounted for.
Close up all access points to the 2ry pass flue gas passages.
The support bracket and lug plate weld joints are to be inspected for
cracking visually and by NDT.

Reheater Outlet Header (3-4)


The reheater outlet header, which is located outside of the flue gas
path in the space between the furnace baffle wall panel and the
furnace front wall panel, has to be inspected for any external corrosion
of material.
1

Remove the header inspection nozzle caps and using a fiberscope,


inspect the inside of the Reheater header for excess wear, damage
to the inlet pipe nozzles, the drain pipe and the reheater tube
nozzles. Remove the accumulated scale deposits.

In locations where the header inspection nozzle caps have been


removed to provide access for internal inspection of the header, weld
preparations are to be machined on the header nozzle and on the cap.
The cap is to be rewelded to the nozzle at a location approximately
10 mm from the original weld. Welds are to be subjected to NDT and/
or hydrostatic test as required by the local regulations.
Ensure that all scaffolding, walkways and associated equipment has
been removed from the furnace and flue gas passages, and has all
been accounted for.
Close up all access points to the header.
The support bracket and lug plate weld joints are to be inspected for
cracking visually and by NDT.

Primary Reheater Lower and Upper Tubes (3-2 & 3-5)


Inspect the outside surface of all primary reheater tube elements and
the hanger tubes visually for signs of burn damage, corrosion,
deformation and cracks. Perform an ultrasonic and an NDT test where
corrosion, deformation or cracks are apparent. Perform an ultrasonic
thickness survey to confirm tube thickness.
Boiler
Mitsubishi

5-16

Chapter 5

Disassembly and Reassembly

Inspect visually all sliding & fixed spacers and seismic ties, stopper
tube sleeves, stopper plates, etc., for heat damaged or missing
spacers and then perform an NDT.
Inspect visually all the economizer hanger tubes passing through the
elements for signs of excessive erosion.

Secondary Reheater Tubes (3-6)


1

Inspect visually the outside surface of all secondary reheater tube


elements for signs of erosion, corrosion, deformation and cracks.
Perform ultrasonic and NDT where erosion, corrosion, deformation
or cracks are apparent and on areas of missing or deformed
attachments. Perform ultrasonic test to confirm tube thickness.

c)

Inspect visually all rod & bar spacers, stopper tube sleeves,
support plates, etc., for heat damaged or missing spacers and then
perform an NDT.

Inspect visually all the 1ry superheater hanger tubes passing


through the elements for signs of excessive erosion.

Inspect the access doors for signs of heat damage or flue gas
leakage.

Check the block insulation and door seals and repair or replace as
necessary.

Reassembly
1

Make sure that all scaffolding, walkways and associated equipment


has been removed from the furnace and flue gas passages and has
all been accounted for.

Close up all access points to the furnace and flue gas passages.

5.3.1 Recommended 10 Year Inspection


It is a standard practice that insurers of power plant and some
governmental authorities insist on certain periodic statutory surveys
and inspections. Irrespective of these statutory requirements, it is
recommended that additional checks be performed on selected items
after a 10 year period of operation.
The following inspections are those applicable to the reheater headers
and tubes, and are to be performed at a suitable time during an
arranged major outage.

Boiler
Mitsubishi

5-17

Chapter 5

Disassembly and Reassembly

Note
Refer to Figure 5-1 for identification of inspection areas of
the boiler.

Primary Reheater Inlet Header (3-1)


1

Perform a visual inspection and a non-destructive examination on


all support bracket and lug weld joints for indications of cracking.

Remove the header inspection nozzle caps and perform an


internal inspection using a fiberscope. The header caps are to be
replaced following the procedure described in GENERAL at the
end of Section 5.4.1 (Page 5-21).

Inspect visually all the nozzle weld joints for signs of cracking.

Perform NDT inspection on 10% of all primary reheater tube


nozzles.

Reheater Outlet Header (3-4)


1

Perform visual inspection and non-destructive examination on all


support plate weld joints for indications of cracking.

Remove the header inspection nozzle caps and perform an


internal inspection using a fiberscope.

Inspect visually all the nozzle weld joints for signs of cracking.

Perform NDT inspection on 10% of all secondary reheater tube


nozzles and drain nozzles.

In locations where header inspection nozzle caps have been removed


to provide access for internal inspection of the header, weld
preparations are to be machined on the header nozzle and on the cap.
The cap is to be rewelded to the nozzle at a location approximately
10 mm from the original weld. Welds are to be subjected to NDT or
hydrostatic test. Make sure that all scaffolding, walkways and
associated equipment has been removed from the furnace and flue gas
passages and has been accounted for.
Close up all access points to the furnace and flue gas passages.

Boiler
Mitsubishi

5-18

Chapter 5

5.4

Disassembly and Reassembly

Economizer Headers and Tubes

CAUTION
Prior to carrying out any maintenance, make sure that the
boiler is shutdown, cooled and all isolations are in place.

a)

Preparation
If economizer header and tube inspection and repair become necessary,
all associated equipment shall be mechanically and electrically isolated
and an authorized clearance and work permit shall be in place prior to the
commencement of work. The following points are also to be considered
when preparing for disassembly and reassembly:
Collect all necessary drawings (assembly drawings, sectional
drawings, part details, etc.) and documents (log sheets, field record
book, etc.) prior to start of work.
Prepare the necessary handling facilities (e.g. suitable lifting
equipment, trolley and supports, etc.) to remove and store the various
parts of the equipment.

b)

Disassembly
Refer to Figures 5-11 & 5-12.
All data is to be recorded during headers and tubes inspection and
removal.
Access to the secondary pass requires suitable scaffolding and walkways.
Economizer headers, inlet and outlet pipes, finned tubes and drain & vent
lines are to be inspected for corrosion, cracking or damage that has
occurred during operation. This external inspection is done visually,
incorporating NDT when in doubt.

Economizer Inlet and Outlet Headers & Distribution Pipe


(4-1, 4-2 & 4-3)
1

Inspect visually the economizer inlet header support bracket weld


joints for signs of cracking and perform NDT.

Economizer Tubes (4-4)


1

Boiler
Mitsubishi

Inspect all economizer tube panels and fins visually for signs of
erosion, corrosion, deformation and cracks.

5-19

Chapter 5

Disassembly and Reassembly

Perform a visual and a dye penetrant examination of the weld joints of


the economizer tube support plates, support lugs, and stopper plates
for signs of burn damage.

Inspect visually the Y tubes of the hanger tubes (5-5) for signs of
erosion, corrosion and cracks and perform an NDT wherever
necessary.

Inspect the economizer access doors for signs of heat damage or flue
gas leakage.

c)

Check the block insulation and door seals and repair or replace as
necessary.

Reassembly
1

Make sure that all scaffolding, walkways and associated equipment


have been removed from the economizer zone and flue gas passages
and ensure that they have been accounted for.

Close up all access points to the economizer and flue gas passages.

5.4.1 Recommended 10 Year Inspection


It is a standard practice that insurers of power plant and some
governmental authorities insist on certain periodic statutory surveys
and inspection. Irrespective of these statutory requirements, it is
recommended that additional checks be performed on selected items
after a 10 year period of operation.
The following inspections are those applicable to the economizer
headers and tubes and are to be performed at a suitable time during an
arranged major outage.

Note
Refer to Figure 5-1 for identification of inspection
areas of the boiler.

Economizer Inlet Header (4-1)

Boiler
Mitsubishi

Inspect visually all nozzle weld joints for signs of cracking.

Perform an NDT inspection on 10% of all economizer tube


nozzles and the three economizer inlet pipe nozzles.

Remove the header inspection nozzle caps and perform internal


inspection using a fiberscope.

5-20

Chapter 5

Disassembly and Reassembly

Economizer Outlet Header (4-3)


1

Remove the header inspection nozzle caps and perform an


internal inspection using a fiberscope.

Inspect visually all nozzle weld joints for signs of cracking.

Perform dye penetrant test on 10% of the economizer hanger


tube nozzles and on the two economizer outlet pipe nozzles.

Economizer Tubes (4-4)


1

Inspect all economizer tube panels and economizer hanger tubes


visually for signs of erosion, corrosion, deformation and cracks.
Perform an ultrasonic and dye penetrant test where erosion,
corrosion, deformation or cracks are excessive and on areas of
missing or deformed attachments. Perform an ultrasonic test to
confirm tube thickness.

General
In locations where header inspection nozzle caps have been removed
to provide access for internal inspection of the header, weld
preparations are to be machined on the header nozzle and on the cap.
The cap is to be rewelded to the nozzle at a location approximately
10 mm from the original weld. Welds are to be subjected to NDT or
hydrostatic test.
Make sure that all scaffolding, walkways and associated equipment
have been removed from the economizer zone and the flue gas
passages and ensure that they have all been accounted for.
Close up all access points to the economizer and flue gas passages.

Boiler
Mitsubishi

5-21

Chapter 5

5.5

Disassembly and Reassembly

Sample Tube Removal


It is necessary to remove and inspect sample pieces of water wall tube during
the first up to the third year period. Consecutively sample tube must be removed
every year. The second year sample is to be removed from the first tube on the
right side of the initial tube; the third year sample to be removed is from the first
tube on the left side of the initial tube; the fourth sample to be removed is from
the second tube on the right side of the initial tube and so on in the consecutive
years. The water wall tube sample locations for the first removal (and the
reference tube for the consecutive removals) are identified in the Figure 4-1.
The sample tube pieces must be 1,000 mm in length and must be inspected and
tested as follows:
Check the thickness, amount and composition of the scale.
Measure the outside diameter and thickness of the tube.
Check the mechanical properties and composition of the tube.
Carry out an acid dissolve test of the scale.
Cut sample tube pieces using a portable reciprocating saw. If this is not possible,
gas cutting equipment may be used.
Removal of tube by use of a grinder is to be avoided.
If the tube is removed by gas cutting, the sample piece must be slightly longer
than necessary to avoid the effects of slag or heat on the tube material and
scale.

a)

Preparation
If sample tube removal becomes necessary, isolate all associated
equipment mechanically and electrically.
An authorized work permit and valid isolation certificate must be in place
prior to the start of work.
The following points must be considered while preparing for disassembly
and reassembly:
Collect all necessary drawings and documents (log sheets, field
record book, etc.) prior to the start of work.
Prepare tools, chain block, slings, scaffolding and ladders.

Boiler
Mitsubishi

5-22

Chapter 5

b)

Disassembly and Reassembly

Tube Removal
The sample tube removal procedure is as follows:
1

Locate and mark (using chalk) the position of the cutting points on the
inside and outside of the furnace by measuring from specified
reference points.

Using the cutting equipment, cut the tube at either side and at each
end of the sample piece.

Cut the sample piece at the lower point first, and then insert a piece of
thin sheet into the cut to minimize debris falling into the tube.

c)

Boiler
Mitsubishi

If necessary, secure the sample section to prevent it falling when the


top cut is made.

Cut the sample piece at the upper point and remove the tube piece.

Pass the tube section to the appropriate department for testing.

Tube Change
1

Prepare the ends of the removed tube for welding. Avoid any debris
falling into the lower water wall section.

Measure the length of the open section after the weld ends have been
squared and chamfered.

Cut and prepare the new section of tube for welding.

Weld the new section in place in accordance with tube approved


welding procedure.

Arrange for a hydrostatic test to be performed on the boiler before


returning it to service.

Make sure all tools are removed from the furnace and all are
accounted for.

5-23

Disassembly and Reassembly

MM-M01.01

Rev.004

Chapter 5

FIGURE 5-1
Boiler
Mitsubishi

INSPECTION AREAS OF BOILER

5-24

Chapter 5

Disassembly and Reassembly

FRONT WALL
INTERMEDIATE MANILFOLD

SIDE W ALL
INTERMEDIATE
OUTLET HEADER

FRONT W ALL
OUTLET HEADER

A.A PORT OPENING

BURNER OPENING
FURNACE
INTERMEDIATE
HEADER
(SIDE W ALL)

SIDE WALL
OUTLET HEADER

FRONT W ALL
INTERMEDIATE
OUTLET HEADER

SIDE W ALL TUBE

FURNACE
INTERMEDIATE
HEADER
(FRONT WALL)

DETAIL 'A'

FRONT W ALL
INTERMEDIATE MANILFOLD

'A'
SIDE W ALL
INTERMEDIATE MANILFOLD

SIDE W ALL
INLET HEADER

'B'

FRONT W ALL TUBE

BURNER OPENING

FURNACE
INTERMEDIATE
HEADER

SIDE W ALL
INTERMEDIATE
OUTLET HEADER

DETAIL 'B'

MPTD-3-0120

SIDE W ALL
INLET HEADER

MM-M01.01

Rev.004

(SIDE W ALL)

FIGURE 5-2
Boiler
Mitsubishi

OVERVIEW OF FURNACE WALLS

5-25

Chapter 5
S1

67 8 6
38 93 .5

79 21
39 3 8.2 5

79 21

3 80 4.75

38 71 .5

22 69 .5

39 3 8.2 5

S E C O N D A R Y P A S S S ID E W A LL

1 43 35

60 22
5 00 6.25

38 93 .5

28 9 5.5

32 93

+6 45 0 0
+ 63 20 0
RO O F TUBE

S3

38 7 4.5

42 7 2

25 9 5.5

S ID E W A LL
O UTLET HDR.
2 -O 32 3.8

F R O N T W A L L O U TL E T H D R .
1 -O 32 3.8

H A N G E R TU B E
(E X C E P T FO R B E N D TU B E )
O 3 8.1 xt9.9

10 0 0

11 57 0

B O IL E R F R O N T

67 8 6

38 04 .7 5

S2

P A S S A G E S ID E W A L L

10 00

29 41 4

Disassembly and Reassembly

3 42 6.5

2 72 5.62 5

65 6 3.75
2 44 7.5

33 3 7.5

30 59 .3 7 5

S ECO ND ARY PASS


S ID E W A L L O U T L E T H D R .
2 -O 21 9 .1

P A S S A G E S ID E
W A L L O U TL E T H D R .
2 -O 21 9 .1

R O O F IN LE T H D R .
1 -O 21 9.1
+6 42 0 0

+6 47 5 0

+6 4 60 0

+6 47 5 0

+6 4 50 0

S3

+6 3 20 0
ROO F TUBE

+ 62 63 0
O 4 5.0 O 5 7.1

8 8.7 5

2 1 9x 13 3.5 = 29 2 36 .5

25 .2 5
4 4.5
4 4.2 5

44 .5

86 x 44 .5
=3 82 7

86 x 44 .5
=3 8 27

44 .5

44 .5

86 x 44 .5
= 38 27

86 x 44 .5
=3 82 7

44 .5

50 x 44 .5
=2 2 25

44 .5

86 x 44 .5
=3 82 7

6 4x 4 4.5=2 84 8

44 .5

86 x4 4 .5
=3 8 27

86 x 44 .5
=3 82 7

ROO F O UTLET
HEADER
1 -O 6 1 0.0

+6 1 10 0

+6 08 5 0

88 .7 5

44 .5

7 4x 4 4.5 =3 29 3
44 .5

9 4x 4 4.5 =4 18 3
44 .5

89

86 x 44 .5+ 2 5.25
+ 59 = 39 11 .2 5
25 .2 5

89

27 x 89
= 24 03
59

11 1 .2 5

37 x 89 =3 29 3
89
+ 58 90 0

23 x 11 1.2 5
= 25 58 .7 5

21 x 11 1.25
= 23 3 6.25

1 11 .2 5

1 11 .2 5

3 1x 1 11.25
= 34 4 8.7 5

2 6x 1 11.25
=2 8 92 .5

+5 81 0 0

44 .2 5

77 8 .7 5

S ID E W A L L T U B E 1
D IV IS IO N W A LL

+5 6 30 0
+ 55 10 0

+5 49 0 0

+5 5 10 0
+5 47 0 0
+5 37 0 0

+5 4 70 0

+5 45 0 0
+5 36 0 0

+5 44 0 0
P R IM A R Y S H
IN L E T H D R .
2 -O 45 7.0

+ 53 2 23 .4
+5 22 5 0
30

+5 0 80 0
+5 0 65 0

+5 0 50 0
38 07 .7 5

+4 9 70 0

O P E N IN G F O R
LIF TIN G P LA TF O R M

50

2 -O 2 1 9.1

+ 47 60 0

+4 76 0 0
+4 7 10 0

2 x6 7 -O 3 8 .1 x t8 .9
S A 2 1 3 -T 1 2
F in t6 S A 3 8 7 -1 2 -1

T .V

+4 51 2 0

+5 0 45 0
+5 00 5 0

+4 5 12 0

+ 47 30 0

+4 7 30 0
+4 7 05 0

+4 70 0 0

P R IM A R Y R H
IN L E T H D R .
2 -O 5 5 9.0
+4 28 4 0
+4 24 0 0

+4 2 58 0

+4 2 42 0

+4 23 0 0
+4 11 5 0

+4 11 5 0
A .A PO R T
(4 7 )

A .A P O R T
(2 7 )
O

A .A P O R T
(2 7 )

A .A PO R T
(4 7 )

C
L O F A.A

+3 9 31 5

+3 90 6 1

7 6x 4 4.5
=3 38 2
44 .5

7 6x 4 4.5
=3 3 82
4 4.5

80 x 44 .5
= 35 60
44 .5

+3 7 73 3

9 1x 4 4.5
= 40 49 .5

80 x 44 .5
= 35 60
44 .5

76 x 44 .5
=3 38 2
44 .5

7 6x 44 .5
=3 3 82
44 .5

48 x 44 .5
=2 13 6

44 .2 5

25 .2 5

+3 49 5 0

6 6x 4 4.5 =2 93 7

8 4x 4 4.5=3 7 38
44 .5

8 4x 4 4.5=3 7 38
44 .5

8 4x 4 4.5=3 7 38
44 .5

S E C O N D A R Y P A S S S ID E
W A L L IN L E T H D R .
2 -O 2 1 9.1

25 .2 5

+3 49 5 0

+3 3 60 0
4 4.2 5

34 x 44 .5
=1 51 3
4 4.5

6 6x 4 4.5
=2 9 37

+ 39 46 5

+ 38 15 0
C
L O F A.A

48 x 44 .5
=2 13 6

+ 39 51 5

+3 88 6 5

+ 38 15 0

4 4.2 5

2 R Y P A S S IN L E T
M A N IF O LD A IR V E N T P IP E
(R igh t S ide O n ly)

4 4.5

96 x 44 .5
= 42 72

87 x 44 .5
4 4.5 =3 8 71 .5

8 5x 4 4.5
4 4.5 = 37 82 .5 44 .5

87 x 44 .5
=3 87 1 .5 44 .5

96 x 44 .5
= 42 72

44 .5

66 x 44 .5
=2 9 37

34 x 44 .5
=1 51 3
44 .5

S4

+3 36 0 0

S4

S E C O N D A R Y P A S S S ID E W A L L
1 0 5 -O 3 8 .1 x t8 .9 S A 2 1 3 -T 1 2
F in t6 S A 38 7-1 2 -1

44 .2 5

+ 31 39 1
+ 30 72 9

+3 0 72 9

+3 0 72 9

CL O F O IL B U R N E R S

+3 00 6 7

LEG END
O

(2 6 )

(3 6 )

R ET RA C TA BLE
S O O T B LO W ER
H ALF R ETR A CTAB LE
S O O T B LO W ER

(3 6 )

(26 )

+ 26 45 3
+ 25 79 1

+2 5 79 1

+ 25 79 1

CL O F O IL B U R N E R S

+ 25 12 9

W ALL BLO W ER
GAS TEM PERATURE
PROBE
+ 21 51 5
+ 20 82 8

+2 0 82 8

GAS DRAFT TAP

+2 08 2 8

CL O F O IL B U R N E R S

+ 20 19 1

G A S D R A F T T A P (T S E T )
G A S T E M P E R A T U R E T A P (T S E T )
25 .2 5

+1 65 0 0

6 6x 4 4.5 =2 93 7

8 4x 4 4.5=3 7 38
44 .5

+1 6 50 0

8 4x 4 4.5=3 7 38
44 .5

8 4x 4 4.5=3 7 38

25 .2 5

44 .5

B .L+ 15 6 86

+1 56 8 6

F U R N A C E IN L E T P IP E
2 -O 4 5 7.0
+1 22 0 0
4 4.2 5
44 .5

44 .5

44 .5

50 x 44 .5
=2 22 5
44 .5

4 4.5

86 x4 4 .5
=3 8 27
44 .5

86 x 44 .5
=3 82 7
44 .5

+1 2 20 0

+1 2 00 0

44 .2 5
L E F T S ID E O N L Y

ACCESS DOOR
O 610
ACCESS DOOR
8 0 0 x 8 0 0 (S ID E W A L L B O T T O M )
O B S E R V A T IO N P O R T
100x250
T E L E V IS IO N P O R T

R IG H T S ID E O N LY

C
L O F BO IL ER

+ 78 33 .3

+7 8 33 .3
+ 71 33 .3

Rev.004

+7 1 33 .3
44 .5
3 27 x 44 .5 =14 5 51 .5

10 0 0 80 0

3 31 x 44 .5 =14 7 29 .5

44 .2 5
29 41 4

S 1 -S 1
MM-M01.01

S ID E W A L L IN L E T H D R .
1 -O 21 9.1

80 0 10 0 0
4 4.2 5

1 80 0

18 00
F R O N T W A L L IN L E T H D R .
1 -O 21 9 .1

FR O N T W ALL
M P T D -3-01 21 -1

6 6 0 -O 2 8 .6

F in t6 S A 3 8 7-1 2 -1

S1

S ID E W A L L
2 x3 2 2 -O 2 8 .6 S A 2 1 3 -T 1 2
F in t6 S A 3 8 7 -1 2 -1

FIGURE 5-3
Boiler
Mitsubishi

S2

FURNACE WALL TUBE PANEL ARRANGEMENT 1/2

5-26

Chapter 5

Disassembly and Reassembly

29404.5
ROOF TUBE(FRONT)
440-O38.1xt7.4

14702.25

1270

3738

3738

2937

3738

3738

3738

ROOF TUBE(REAR)220-O57.1xt8.9 SA213-T12

ROOF TUBE(FRONT)440-O45.0xt7.4 SA213-T12

3888.75
REAR WALL
HANGER OUTLET HDR.
1-O219.1

400.5

FIN t6 SA387-12-1

BOILER FRONT

580

FIN t9 SA387-12-1

10140

4295

1000

+41150
A.A PORT
(47 )

A.A PORT
(27 )

10150

C
L OF A.A

+39061

C
L OF A.A

+37733

1300

84

300

C
L OF 2RY PASS
SIDE WALL

133.5

25x133.5
=3337.5

51x66.75
=3404.25
66.75

133.5

14702.25

27x133.5
=3604.5

55x66.75
=3671.25
66.75

133.5

27x133.5
=3604.5

55x66.75
=3671.25
66.75

66.75

6022

5006.25

CL OF 2RY PASS
DIVISION WALL

27x133.5
=3604.5

55x66.75
=3671.25

14335

A.A PORT
(47 )

A.A PORT
(27 )

C
L OF 2RY PASS
FRONT WALL

+44310

CL OF BOILER

CL OF REAR WALL

1370

+44971.8

C
L OF FURNACE

+45120

CL OF FRONT WALL

422.75

33.375

44.25
57x66.75
=3804.75
66.75

86x44.5=3827

31x66.75 31x66.75
=2069.25 =2069.25
66.75
66.75

+50500

86x44.5=3827

39x66.75
=2603.25
66.75

57x66.75
=3804.75
66.75

14707

4.75

39x66.75
=2603.25

4.75

57x66.75
=3804.75
66.75

3200

REAR WALL
HANGER INLET HDR.
1-O219.1

29414

ROOF INLET HDR.


1-O219.1

+53700

31x66.75 31x66.75 31x66.75


=2069.25 =2069.25 =2069.25
66.75
66.75
66.75

57x66.75
=3804.75
66.75

285.85

33x66.75
=2202.75

10900

O48.6xt11.2 SA213T12

108x267=28836
REAR WALL HANGER TUBE

4313.75

370

C
L OF PASSAGE
SIDE WALL

C
L OF SIDE WALL

284.25

320

4.75

55.375

55.375

370

+63200
ROOF TUBE

O28.6xt5.3
SA213T12
(Smooth Tube)

2320

MEMBRANE

+64200

11520

4956.25

MEMBRANE

+64600

44.25

FIN t6 SA387-12-1

5332

29404.5

3888.75

CL OF 2RY PASS
REAR WALL

14702.25

6563.75

ROOF OUTLET HDR.


2-O610.0

1000

S3-S3

+38150

57466.7

44.25

80x44.5
=3560

76x44.5
=3382
44.5

76x44.5
=3382
44.5

48x44.5
=2136
44.5

91x44.5
=4049.5

48x44.5
=2136
44.5

76x44.5
=3382
44.5

76x44.5
=3382
44.5

80x44.5
=3560

44.25

+34950

34x44.5
=1513
44.5

85x44.5
=3782.5

96x44.5
44.5 =4272 44.5

68x44.5
=3026

85x44.5
44.5 =3782.5 44.5

68x44.5
=3026

44.5

96x44.5
=4272 44.5

26

O28.6xt5.7 SA213T12 (Rifle Tube)

+33600
44.25

34x44.5
=1513
44.5

85x44.5
=3782.5

44.25

+31391
+30729

+30729

BOILER FRONT

C
L OF OIL BURNERS

+30067

(36 )

(26 )

(26 )

(36 )
C
L OF OIL BURNERS

+20828

C
L OF OIL BURNERS

26

+25791

CL OF FURNACE

17100

+25791

+26453
+25129

CL OF BOILER
+21515
+20828

36

+20191

MEMBRANE

180

44.5

44.5

44.5

86x44.5
=3827
44.5

44.5

86x44.5
=3827
44.5

44.25
o

50x44.5
=2225
44.5

36

44.25

MEMBRANE

9366.7

O28.6xt5.7 SA213T12 (Smooth Tube)

+16500
B.L+15686

CL OF BOILER

+7833.3

Rev.004

+7133.3
44.5
327x44.5=14551.5

1000 800

331x44.5=14729.5
29414

MM-M01.01

400.5

S2-S2
MPTD-3-0121-2

Boiler
Mitsubishi

800 1000
44.25

44.25
1800

REAR WALL
660-O28.6 Fin t6 SA387-12-1

S4-S4

1800
REAR WALL INLET HDR.
1-O219.1

FIGURE 5-4

FURNACE WALL TUBE PANEL ARRANGEMENT 2/2

5-27

Chapter 5

FIGURE 5-5

Boiler
Mitsubishi

Disassembly and Reassembly

OVERVIEW OF PASSAGE WALLS

5-28

Chapter 5

Disassembly and Reassembly

PASSAGE SIDE W ALL OUTLET HDR

PASSAGE SIDE W ALL INLET HDR


NOTE: OPPOSITE SIDE IS MIRROR IMAGE.

TUBE(SMOOTH)

SA213-T12

(m m)
38.10

(mm)
8.90

M pa(g)
30.11

C
450

(m m)
8.90

(mm )
5.05

M PTD -4-0123

FIGURE 5-6
Boiler
Mitsubishi

PASSAGE WALL PANEL ARRANGEMENT

5-29

Disassembly and Reassembly

MM-M01.01

Rev.004

Chapter 5

FIGURE 5-7
Boiler
Mitsubishi

OVERVIEW OF 2RY PASS WALL

5-30

Chapter 5

Disassembly and Reassembly

SECONDARY PASS FRONT WALL


OUTLET HEADER

C
L OF BOILER

SECONDARY PASS FRONT WALL


INLET HEADER

VIEW FROM BOILER FRONT

1
2

SCREEN TUBE
TUBE(SMOOTH)

SA213-T12
SA213-T12

(mm)
45
38.10

(mm)
7.40
8.90

Mpa(g)
29.80
29.80

C
460
460

(mm)
7.40
8.90

(mm)
5.96
5.04

MPTD-4-0125-1

FIGURE 5-8
Boiler
Mitsubishi

2RY PASS WALL PANEL ARRANGEMENT (1/3)

5-31

Chapter 5

Disassembly and Reassembly

SECONDARY PASS
REAR WALL OUTLET HDR
C
L OF BOILER

SECONDARY PASS
REAR WALL INLET HDR

VIEW FROM BOILER REAR

TUBE (SMOOTH)

SA213-T12

(mm)
38.10

(mm)
8.90

Mpa(g)
29.80

C
460

(mm)
8.90

(mm)
5.04

MPTD-4-0125-2

FIGURE 5-9
Boiler
Mitsubishi

2RY PASS WALL PANEL ARRANGEMENT (2/3)

5-32

Chapter 5

BOILER FRONT

Disassembly and Reassembly

SECONDARY PASS SIDE


WALL OUTLET HDR.

SECONDARY PASS SIDE


WALL INLET HDR.

NOTE: OPPOSITE SIDE IS MIRROR IMAGE.

TUBE (SMOOTH)

SA213-T12

(mm)
38.10

(mm)
8.90

Mpa(g)
29.80

C
460
O

(mm)
8.90

(mm)
5.04

MPTD-4-0125-3

FIGURE 5-10
Boiler
Mitsubishi

2RY PASS WALL PANEL ARRANGEMENT (3/3)

5-33

Disassembly and Reassembly

MM-M01.01

Rev.004

Chapter 5

FIGURE 5-11
Boiler
Mitsubishi

OVERVIEW OF ECONOMIZER ASSEMBLY


5-34

Chapter 5

FIGURE 5-12
Boiler
Mitsubishi

Disassembly and Reassembly

ECONOMIZER BANK ARRANGEMENT

5-35

Disassembly and Reassembly

MM-M01.01

Rev.004

Chapter 5

FIGURE 5-13
Boiler
Mitsubishi

OVERVIEW OF ROOF TUBE WALLS

5-36

Chapter 5
A

BOILER FRONT

"f"

Disassembly and Reassembly

SEAL BAR

SEAL WELD

SIDE WALL TUBE


PASSAGE SIDE
WALL TUBE
2RY PASS
SIDE WALL TUBE

"e"

"e"

SEAL BAR
SEAL WELD
ROOF TUBE

A-A
(B-B)
(SIDE WALL TUBE AND ROOF TUBE SEAL)

"e"

Roof Tube(Rear)

"e"

PASSAGE SIDE WALL TUBE


2RY PASS
SIDE WALL TUBE

INSULATION

ROOF TUBE

"e"

"e"

REFRACTORY

C-C
(ECO. HANGER TUBE BELLOW)
2RY PASS
SIDE WALL TUBE

2RY SH INLET HDR

2RY PASS
REAR WALL TUBE

ECO. HANGER
TUBE

1RY SH TUBE

ROOF TUBE
PAD

PAD

REFRACTORY

S6

D-D
(2RY PASS DIVISION WALL BELLOWS)

1RY SH
OUTLET HDR

ECO. HANGER
TUBE
ECONOMIZER
OUTLET HDR

2RY PASS

ECO. HANGER
TUBE

1RY RH TUBE
1RY RH
OUTLET HDR

2RYRH
OUTLET HDR

2RY PASS

2RY SH TUBE
2RY RH
INLET HDR

3RY SH
INLET HDR

3RY SH
OUTLET HDR

3RY SH TUBE

REAR WALL
HANGER TUBE

"a"

ECO. HANGER
TUBE

INSULATION

PASSAGE SIDE
WALL TUBE
BELLOWS PLATE

S6

2RY SH OUTLET HDR

BOILER FRONT

SEAL BOX
INSULATION

2RY PASS
FRONT WALL
OUTLET HDR

REAR WALL
HANGER
OUTLET HDR

FRONT WALL
OUTLET HDR
ROOF INLET HDR

2RY PASS
DIVISION WALL
OUTLET HDR

BELLOWS

DETAIL "e"

2RY PASS REAR


WALL OUTLET HDR

ROOF TUBE

REFRACTORY

BELLOWS

ROOF TUBE

ROOF OUTLET HDR


INSULATION

SLEEVE SEAL

"b"

CL OF FRONT WALL TUBE

SLEEVE SEAL

"c"

CL OF REAR WALL HANGER TUBE

S1

E-E

(REAR WALL HANGER TUBE BELLOWS)

ROOF TUBE

ROOF TUBE

"d"

SLEEVE SEAL

CL OF 2RY PASS FRONT WALL TUBE

"d"

SLEEVE SEAL

S6 -S 6

C
L OF 2RY PASS DIVISION WALL TUBE

PASSAGE SIDE
WALL TUBE

CL OF 2RY PASS REAR WALL TUBE

INSULATION

BELLOWS PLATE

INSULATION

S5
SEAL COLLAR

SEAL PLATE
SEAL BOX

ROOF TUBE

ROOF TUBE

INSULATION

REFRACTORY

SLEEVE

REFRACTORY

REFRACTORY

ROOF TUBE

S1

S1-S1

S5

DETAIL "a"

DETAIL "f"

2SH

F-F

(SECONDARY PASS FRONT WALLTUBE BELLOWS)

INSULATION

S5 -S5

REFRACTORY

S3

SPACER TUBE

S4
SEAL COLLAR

SEAL COLLAR

SEAL BOX

BELLOWS PLATE
SEAL COLLAR
SEAL PLATE

BELLOWS PLATE
ROOF TUBE

S2

REFRACTORY

ROOF TUBE

SIDE WALL SECTION


BELLOWS(RIGHT & LEFT SIDE 4 PANELS)

NORMAL

Rev.004

SEAL PLATE
BELLOWS
SEAL BOX
ROOF TUBE

S2

DETAIL "b"
3SH

MPTD-3-0129

Boiler
Mitsubishi

NORMAL

SECTION

BELLOWS

NORMAL

BELLOWS
SIDEWALL(INLET HDR) 4 PANELS x2
SIDE WALL(OUTLET HDR) 6 PANELS x2
BOILER CNTERr 6 6 PANELS x2

S3

REFRACTORY

MM-M01.01

REFRACTORY
ROOF TUBE

BELLOWS PLATE

SEAL COLLAR

INSULATION

SEAL BOX

BELLOWS

REFRACTORY

BELLOWS

NORMAL

INSULATION

BELLOWS

SEAL PLATE

DETAIL "c"

NORMAL

S4-S4

S4
DETAIL "d"

S 3-S 3

1SH,1RH

2RH

S2-S2

FIGURE 5-14

ARRANGEMENT OF ROOF PENETRATION SEALING

5-37

Disassembly and Reassembly

MM-M01.01

Rev.004

Chapter 5

FIGURE 5-15
Boiler
Mitsubishi

OVERVIEW OF 1RY SUPERHEATER ASSEMBLY


5-38

Chapter 5

Disassembly and Reassembly

BO ILE R FR O NT

TU BE

SA213-T12

(m m )
45

(m m )
6.90

M pa(g)
28.61

C
494
O

(m m )
6.90

(m m )
6.32

M PTD-4-0131

FIGURE 5-16
Boiler
Mitsubishi

1RY SUPERHEATER BANK ARRANGEMENT

5-39

Disassembly and Reassembly

MM-M01.01

Rev.004

Chapter 5

MPTD-4-0132

FIGURE 5-17
Boiler
Mitsubishi

OVERVIEW OF 2RY SUPERHEATER ASSEMBLY


5-40

Disassembly and Reassembly

MM-M01.01

Rev.004

Chapter 5

MPTD-3-0133

FIGURE 5-18
Boiler
Mitsubishi

2RY SUPERHEATER BANK ARRANGEMENT

5-41

Disassembly and Reassembly

MM-M01.01

Rev.004

Chapter 5

FIGURE 5-19

Boiler
Mitsubishi

OVERVIEW OF 3RY SUPERHEATER ASSEMBLY

5-42

Chapter 5

Disassembly and Reassembly

TERTIARY S.H. OUTLET HDR.


TERTIARY S.H. INLET HDR.

FIGURE 5-20
Boiler
Mitsubishi

3RY SUPERHEATER BANK ARRANGEMENT

5-43

Disassembly and Reassembly

MM-M01.01

Rev.004

Chapter 5

MPTD-4-0136

FIGURE 5-21
Boiler
Mitsubishi

OVERVIEW OF 1RY REHEATER ASSEMBLY

5-44

Chapter 5

Disassembly and Reassembly

PRIMARY REHEATER
INLET HEADER

1
2
3
4
5
6
7

TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE

SA213-T12
SA213-T12
SA213-T22
SA213-T22
C ASE 2115-1
C ASE 2328-1
SA213-T12

(mm)
57.10
57.10
57.10
57.10
57.10
57.10
57.10

(mm)
3.50
4.50
4
4.50
4
3.50
4

Mpa(g)
5.84
5.84
5.84
5.84
5.84
5.84
5.84

C
451
451
516
516
547
605
537
O

(mm)
3.50
4.50
4
4.50
4
3.50
4

(mm)
1.87
1.87
2.57
2.57
1.36
1.69
3.35

MPTD-4-0137

FIGURE 5-22
Boiler
Mitsubishi

1RY REHEATER BANK ARRANGEMENT

5-45

Disassembly and Reassembly

MM-M01.01

Rev.004

Chapter 5

MPTD-4-0138

Boiler
Mitsubishi

FIGURE 5-23

OVERVIEW OF 2RY REHEATER ASSEMBLY

5-46

Chapter 5

Disassembly and Reassembly

1
2
3
4
5
6
7
8
9
10

TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
INLET NOZZLE
INLET NOZZLE
OUTLET NOZZLE

SA213-T12
CASE 2115-1
CASE 2328-1
CASE 2115-1
SA213-T91
SA213-T22
SA213-T12
SA213-T12
SA213-T12
SA213-T91

(mm)
57.10
57.10
57.10
57.10
57.10
57.10
57.10
57.10
38.10
57.10

(mm)
3.50
3.50
3.50
4.50
4.50
4.50
13
3.50
3.50
4.50

Mpa(g)
5.84
5.84
5.84
5.84
5.84
5.84
5.84
5.90
5.90
5.90

o
C
496
496
657
624
624
561
496
496
496
624

(mm)
3.50
3.50
3.50
4.50
4.50
4.50
13
3.50
3.50
4.50

(mm)
2.08
1.33
2.48
2.06
3.68
4.01
2.08
2.10
1.40
3.71

MPTD-4-0139

FIGURE 5-24
Boiler
Mitsubishi

2RY REHEATER BANK ARRANGEMENT

5-47

Chapter 5

Disassembly and Reassembly

ITEM

TOP

TOP

7
4

S1-S1

S2-S2

DESCRIPTION

DE-SUPERHEATER BODY

SPRAY PIPE NOZZLE

SPRAY PIPE REDUCER

LINER PIPE

REINFORCING PAD T12

POSITIONING BOLT

SUPPORT BOLT

PROTECTION NOZZLE

PROTECTION NOZZLE END PLATE

10

INSPECTION NOZZLE

11

INSPECTION NOZZLE END PLATE

12

WATER SPRAY PIPE

13

WATER SPRAY PIPE

14

SPRAY NOZZLE

15

NOZZLE HOLDER

16

POSITIONING ROD

17

POSITIONING RING T12

18

POSITIONING RING T14

19

REINFORCING LUG T12

TOP

14

SH PRIMARY
DE-SH OUTLET PIPE

S1

19

12

17

S2

13
SH PRIMARY
DE-SH INLET PIPE

15
FLOW

10

S1

S2
8

18

16

11

10

11

MPD-4-0140

FIGURE 5-25
Boiler
Mitsubishi

SECTIONAL VIEW OF DESUPERHEATER FOR SUPERHEATERS

5-48

Chapter 5

Disassembly and Reassembly

ITEM

3
18

DESCRIPTION

DESUPERHEATER BODY

SPRAY PIPE NOZZLE

SPRAY PIPE REDUCER

WARMING PIPE NOZZLE

LINER PIPE

PROTECTION NOZZLE

PROTECTION NOZZLE END PLATE

INSPECTION NOZZLE

INSPECTION NOZZLE END PLATE

10

REINFORCING PAD t12

11

POSITIONING BOLT

12

SUPPORT BOLT

13

BOSS

14

POSITIONING ROD

15

SPRAY WATER PIPE

16

SPACER

17

SPRAY WATER GUIDE

18

SPRAY NOZZLE

19

SPRAY PIPE NOZZLE

2
12

16
17

13

11
5

10

13
5

19

10

15

11

14
7

9
8

MPTD-4-0141

FIGURE 5-26

Boiler
Mitsubishi

SECTIONAL VIEW OF DESUPERHEATER FOR REHEATER

5-49

Disassembly and Reassembly

MM-M01.01

Rev.004

Chapter 5

FIGURE 5-27
Boiler
Mitsubishi

CABLE OPENING ARRANGEMENT FOR ROOF AND NOSE SECTION

5-50

Disassembly and Reassembly

MM-M01.01

Rev.004

Chapter 5

FIGURE 5-28
Boiler
Mitsubishi

ASH PROTECTOR ARRANGEMENT FOR BOILER TUBES

5-51

Chapter 5

Disassembly and Reassembly

29414
164x178=29192

111

111
14335
7167.5

7167.5

SIDE WALL INLET


HEADER (LEFT SIDE)

CL OF RIGHT SIDE
WALL TUBE

CL OF BOILER
14738

14738
29476

FHFI-2

29414
111

111
14707

164x178=29192

3167.5

C
L OF BOILER
FRONT WALL INLET HEADER
FHFI-1
C
L OF FURNACE

(VIEW FROM BOILER FRONT)

29414

FHFI-1

4000

REAR WALL INLET HEADER


FHBI-2

14707

+7133.3
CL OF LEFT SIDE
WALL TUBE

4000

FRONT WALL INLET HEADER


FHFI-2

3167.5

REAR WALL INLET HEADER


FHBI-1

380

BOILER FRONT
1800

BOILER FRONT

BOILER FRONT

1800

380

SIDE WALL INLET


HEADER (RIGHT SIDE)

KEY PLAN

+7133.3
CL OF LEFT SIDE
WALL TUBE

CL OF RIGHT SIDE
WALL TUBE

CL OF BOILER
14738

14738
29476

FHBI-1

ORIFICE ASSEMBLY LIST


FHBI-2

(VIEW FROM BOILER FRONT)

O1992
O1872

133.5 133.5

39x178=6942

+- 0.1

A01

92

R1+- 0.1

A02

- 0.1

39x178=6942

+
- 0.1

+0.05

Odo-0.03
COLD SIDE

(250)

TYPICAL ORIFICE
+7133.3

CL OF FURNACE
FRONT WALL TUBE

C
L OF FURNACE
7217.5

7217.5

CL OF FURNACE
REAR WALL TUBE

14435

FHLI-1
A01
8.0

LEFT SIDE SHOWN


(VIEW FROM HOT SIDE)

375

FURNACE WALL INLET


HEADER TUBE NOZZLE
(FRONT,REAR,SIDE)

NAME PLATE FITTING PROCEDURE.

COLD SIDE

(250)

MM-M01.01

Rev.004

CL OF FURNACE
FRONT WALL TUBE

CL OF FURNACE
7217.5

7217.5

A04

12

9.5

A05

13

10.0

A06

14

10.5

A07

15

11.0

A08

16

A09
A10

RIGHT SIDE SHOWN


(VIEW FROM COLD SIDE)

APPLIED
LOCATION

TUBE QUANTITY
MARKS
(SET)

FRONT WALL

REAR WALL

FRONT WALL

18

18

REAR WALL

FRONT WALL

12

REAR WALL

FRONT WALL

38

FRONT WALL

12

REAR WALL

14

FRONT WALL

16

FRONT WALL

12

REAR WALL

14

11.5

FRONT WALL

27

17

12.0

REAR WALL

12

18

12.5

REAR WALL

22

A11

19

13.0

REAR WALL

27

A12

20

13.5

REAR WALL

10

A13

21

15.0

REAR WALL

24

A14

22

16.0

REAR WALL

12

A15

23

18.0

FRONT WALL

12

REAR WALL

12

A16

7.0

LEFT SIDE WALL

12

RIGHT SIDE WALL

12

A17

7.0

LEFT SIDE WALL

RIGHT SIDE WALL

LEFT SIDE WALL

18

RIGHT SIDE WALL

18

LEFT SIDE WALL

23

RIGHT SIDE WALL

23

LEFT SIDE WALL

12

RIGHT SIDE WALL

12

LEFT SIDE WALL

10

RIGHT SIDE WALL

10

LEFT SIDE WALL

RIGHT SIDE WALL

A21

FHRI-1

8.5
9.0

A20

14435

10
11

A19

CL OF FURNACE
REAR WALL TUBE

8.0

A03

A18

+7133.3

C0.5 +-0.2

+- 0.1

92

+- 0.1

+- 0.1

O1812
14335

ASS'Y ORIFICE ORIFICE


NO.
NO. HOLE DIA.

+- 0.1
0
-0.1

A22

8
9
10
11
12

7.5
8.0
8.5
9.0
9.5

MPTD-3-0612

FIGURE 5-29
Boiler
Mitsubishi

ARRANGEMENT OF ORIFICES IN THE FURNACE LOWER HEADER TUBES

5-52

Chapter-6

Corrective Maintenance

C ha pte r

6 Corrective Maintenance
Corrective maintenance means repair or changing work to be performed in case of failure
of the Boiler. Though a well-planned preventive program is able to reduce the probability of
sudden failure, the unscheduled corrective maintenance is still necessary seriousness of
the problem faced. The schedule for repair of equipment must be carefully planed to keep
outage time reduced.
During such repair or changing work, an inspection must be carefully conducted to
determine why the equipment has failed. Good corrective maintenance not only requires
the quick restoration of the failed equipment back into service but also demands every
effort to identify and record the root cause of the failure.
The inspection results will help to find the cause of the failure. The findings, along with
possible rectification proposals are use as a feedback to update the preventive
maintenance procedures.

6.1

Prerequisites
The necessary prerequisites for the schedule maintenance of the steam drum and
tube banks are as follows:

a)

Scheduling
Unlike preventive maintenance, the schedule of corrective maintenance can
only be started after a failure has occurred. Depending on the severity of the
problem, the importance of the service provided by the failed equipment and
availability of manpower, a schedule of the corrective maintenance must be
prepared to solve the problem at the earliest opportunity.
The schedule should clearly indicate the critical path and assign the priority
for different parallel activities. Once the schedule is agreed, be sure to
observe the schedule so that the maintenance should be completed timely.

b)

Departmental Interface/Notification
Refer to Section 4.1.2, Interdepartmental Cooperation and Communication
Notification.

c)

Isolation of Equipment
Refer to Section 4.1.3, Isolation of Equipment.

d)

Safety Precautions
Refer to Section 4.1.4, Safety Precautions.

Boiler
Mitsubishi

6-1

Chapter-6

6.2

Corrective Maintenance

Preparation
a)

Parts, Tools and Equipment


Refer to Subsection 4.2.1 (a), Parts, Tools and Equipment.

b)

Documentation
Refer to Subsection 4.2.1 (b), Documentation.

6.3

Boiler Tube Repair


If a boiler tube has failed, it is necessary to find the location of the failed tube as
quickly as possible. The operator and maintainer must find the location of the failed
tube quickly and inform the Shift Charge Engineer or Maintenance Engineer
immediately.
As soon as the boiler has been shutdown, cooled, and all isolations are in place, the
Shift Charge Engineer must prepare the Permit to Work as required for the
Maintenance Engineer or his assistant to start the work.
The maintainers must be suitably dressed before entering the boiler to find the
faulty tube. If they are not able to find, they must return the boiler to the operator.
The operator must then perform a hydrostatic test to find the leaking tube.
Once the tube leak is found, the maintainers must request their work permit. They
must also install scaffolding as necessary for gaining access to the failed tube.
When the failed tube is found, the maintainer can prepare the required insert,
remove the failed tube, arrange for a welder and install the new tube/ tubes.
On completion of the welding and based on the location of the failure, the operator
will perform a hydrostatic test or a NDT of the weld.
The scaffolding can then be removed from the boiler, the access doors can be
closed and the Permit to Work returned to the Shift Charge Engineer.

6.4

Troubleshooting
This section provides information on troubleshooting and the servicing of the boiler
relative to mechanical maintenance.
A table of faults, possible causes and remedies has been provided to assist in
troubleshooting. (Refer to Table 6-1)
For any new kind of problem not listed in the following table, please contact the
manufacturer for assistance.

Boiler
Mitsubishi

6-2

Chapter-6

TABLE 6-1

Corrective Maintenance

TROUBLESHOOTING STEAM DRUM, FURNACE, SUPERHEATER,


REHEATER AND ECONOMIZER

Fault

Possible Cause

Remedy

Abnormal noise in the furnace


or 2RYpass.

Failure of waterwall,
superheater, reheater or
economizer

Shutdown boiler and change


failed tubes. Investigate the
cause for the failure and rectify.

Increase in feed water make up


flow.

Failure of waterwall,
superheater, reheater or
economizer

Shutdown boiler and change


failed tubes. Investigate the
cause for the failure and rectify.

Increase in ID fan current.

Failure of waterwall,
superheater, reheater or
economizer

Shutdown boiler and change


failed tubes.

Pressurization of furnace

Failure of furnace draft controls

Rectify cause for furnace draft


control failure.

Failure of boiler tubes in


furnace zone

Shutdown boiler and replace


failed tubes

External deposits on waterwall


tubes causing poor heat
transfer.

Wall soot blowing operation to


be started or frequency
increased.

Internal scale deposits on


waterwall tubes.

Chemical cleaning of
waterwalls required using
chelates.

Low superheat temperature


combined with high flue gas exit
temperature.

External deposits on
superheater tubes.

Soot blowing in superheater


area is to be started or
frequency increased.

Low reheat temperature


combined with high flue gas exit
temperatures.

External deposits on reheater


tubes.

Soot blowing in reheater area to


be started or increased.

Persistent low economizer


temperature combined with
high flue gas exit temperatures.

External deposits on reheater


tubes.

Soot blowing in economizer


area to be started or frequency
increased.

Abnormal noise in the area of


the boiler.

Safety valves opening or


simmering.

Check boiler operating


pressure and safety valve set
pressure.

Steam leakage from valve


glands or flange joints.

Tighten the valve gland or


remake the flange joint.

Constant usage of poor quality


water.

Acid cleaning of water wall


tubes using a chelating agent.

High furnace temperature or


high fuel consumption
combined with high flue gas exit
temperature and sluggish
steaming.

Blockage of orifices in the water


wall lower headers.

Boiler
Mitsubishi

6-3

Appendix A

Appendix

A Torque Chart
TABLE A-1

TORQUE CHART

Bolt Material Ref.


Westinghouse
Stds.(Corresponding
Required Initial

JIS-SCM435 AISI4137
2

Westinghouse 15106FD
10705BU AISI616

(28 kg/mm )

AISI1690(4290(42kg/mm )

(32kg/mm )
Stress
Bolts Diameter

Torque(kg-m)

Torque(kg-m)

Torque(kg-m)

12

5.4

6.2

8.1

16

10.9

12.5

16.3

19

18.2

20.8

27.0

22

29.2

33.4

43.4

25

44.5

50.8

66.0

29

64.5

73.7

95.8

32

90.7

103.7

134.8

35

123.4

141.0

183.3

38

145.3

166.0

215.8

41

199.5

228.0

296.4

44

272.1

311.0

404.3

48

363.1

415.0

539.5

51

399.0

456.0

592.8

Boiler
Mitsubishi

A-1

Appendix B

Recommended
B Spare Parts

Appendix

Boiler
Mitsubishi

B-1

Appendix B

RECOMMENDED SPARE PARTS

MM-M01.01

Rev.004

TABLE B-1

Boiler
Mitsubishi

B-2

Appendix B

Continued from previous page.


RECOMMENDED SPARE PARTS

MM-M01.01

Rev.004

TABLE B-1

Boiler
Mitsubishi

B-3

Appendix B

Continued from previous page.


RECOMMENDED SPARE PARTS

MM-M01.01

Rev.004

TABLE B-1

Boiler
Mitsubishi

B-4

Appendix B

Continued from previous page.


RECOMMENDED SPARE PARTS

MM-M01.01

Rev.004

TABLE B-1

Boiler
Mitsubishi

B-5

Appendix B

Continued from previous page.


RECOMMENDED SPARE PARTS

MM-M01.01

Rev.004

TABLE B-1

Boiler
Mitsubishi

B-6

Appendix C

Appendix

C Special Tools
No special tools are recommended by the manufacturers for the inspection and maintenance of the
boiler.

Boiler
Mitsubishi

C-1

Appendix D

Appendix

D Applicable Vendor Drawings


There is no applicable vendor drawing.

Boiler
Mitsubishi

D-1

Appendix E

Assembly and Details of


E Refractory, Insulation, etc.

Appendix

1.

ASSEMBLY AND DETAILS OF REFRACTORY AND INSULATION

2.

INSULATION PROCEDURE DETAIL

Boiler
Mitsubishi

E-2
E-136

E-1

Appendix E

Boiler
Mitsubishi

E-2

Appendix E

Boiler
Mitsubishi

E-3

MM-M01.01

Rev.004

Appendix E

Boiler
Mitsubishi

E-4

MM-M01.01

Rev.004

Appendix E

Boiler
Mitsubishi

E-5

Appendix E

Boiler
Mitsubishi

E-6

Appendix E

MM-M01.01

Rev.004

Boiler
Mitsubishi

E-7

Appendix E

MM-M01.01

Rev.004

Boiler
Mitsubishi

E-8

Appendix E

MM-M01.01

Rev.004

Boiler
Mitsubishi

E-9

Appendix E

MM-M01.01

Rev.004

Boiler
Mitsubishi

E-10

Appendix E

MM-M01.01

Rev.004

Boiler
Mitsubishi

E-11

Appendix E

Boiler
Mitsubishi

E-12

Appendix E

MM-M01.01

Rev.004

Boiler
Mitsubishi

E-13

Appendix E

MM-M01.01

Rev.004

Boiler
Mitsubishi

E-14

Appendix E

MM-M01.01

Rev.004

10

Boiler
Mitsubishi

E-15

Appendix E

MM-M01.01

Rev.004

11

Boiler
Mitsubishi

E-16

Appendix E

MM-M01.01

Rev.004

12

Boiler
Mitsubishi

E-17

Appendix E

MM-M01.01

Rev.004

13

Boiler
Mitsubishi

E-18

Appendix E

MM-M01.01

Rev.004

14

Boiler
Mitsubishi

E-19

Appendix E

MM-M01.01

Rev.004

15

Boiler
Mitsubishi

E-20

Appendix E

MM-M01.01

Rev.004

16

Boiler
Mitsubishi

E-21

Appendix E

MM-M01.01

Rev.004

17

Boiler
Mitsubishi

E-22

Appendix E

MM-M01.01

Rev.004

18

Boiler
Mitsubishi

E-23

Appendix E

MM-M01.01

Rev.004

19

Boiler
Mitsubishi

E-24

Appendix E

MM-M01.01

Rev.004

20

Boiler
Mitsubishi

E-25

Appendix E

MM-M01.01

Rev.004

21

Boiler
Mitsubishi

E-26

Appendix E

MM-M01.01

Rev.004

22

Boiler
Mitsubishi

E-27

Appendix E

MM-M01.01

Rev.004

23

Boiler
Mitsubishi

E-28

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