Tanjung Jati B Training

GENERAL INSPECTION
BOILER
GENERAL INSPECTION
BOILER

Tanjung Jati B Training

PT Central Java Power
Tanjung Jati B Unit 1 & 2

2 x 660MW(net)
5,100,000 lb/hr Steam Flow
2514 psi, 1006F / 1001F
B&W Precipitator
B&W Wet FGD

Tanjung Jati B Training

General Inspection
Boiler

This section is intended to point out various areas

or components of the boiler and its auxiliaries which
require attention with regard to routine inspection.

Please consult the Operation and Maintenance manuals

for details.

Tanjung Jati B Training

General Inspection
Boiler

Some items that will be discussed

Steam Drum
Safety Valves
Boiler & Pipe Supports
Expansion Joints
Burner Front
Sootblowers
Air Heater
Fans

Tanjung Jati B Training

General Inspection
Boiler

Some items that will be discussed

Steam Drum
Safety Valves
Boiler & Pipe Supports
Expansion Joints
Burner Front
Sootblowers
Air Heater
Fans

Tanjung Jati B Training

General Inspection
Boiler

STEAM
DRUM

Tanjung Jati B Training

General Inspection
Boiler

STEAM DRUM

The steam drum should be inspected on a regular

basis. A minimum of once per year.

The inspection should focus on internal components

which include the following.

Tanjung Jati B Training

General Inspection
Boiler

STEAM DRUM

Cyclone Cans, Vortex Eliminators, Belly Plates,

Feed Water Piping, Chemical Injection Piping and
Moisture Separators.

We are basically checking to see if anything is loose,

out of place or has broken.

Tanjung Jati B Training

General Inspection
Boiler

MOISTURE
SEPARATORS

CYCLONE
CANS

FEEDWATER
PIPING

BELLY
PLATES VORTEX
ELIMINATORS

Tanjung Jati B Training

General Inspection
Boiler

STEAM DRUM

SPECIAL NOTE: Before entering the steam drum, the

internal atmosphere must be checked for oxygen.

NEVER enter the steam drum with only one door open.

NEVER enter the steam drum with objects in your

pocket. These objects can and will fall down the
downcomers.

Tanjung Jati B Training

General Inspection
Boiler

STEAM
DRUM

DOWNCOMER

Tanjung Jati B Training

General Inspection
Boiler

Some items that will be discussed

Steam Drum
Safety Valves
Boiler & Pipe Supports
Expansion Joints
Burner Front
Sootblowers
Air Heater
Fans

Tanjung Jati B Training

General Inspection
Boiler

SAFETY VALVES

If maintained properly, potential steam leakage

from the valves can be avoided. Please note that
if steam leakage becomes excessive, the boiler
will need to be shutdown for repairs to avoid
excessive damage to valve internals.

Tanjung Jati B Training

General Inspection
Boiler

SAFETY VALVES

Safety valve leakage can occur due to the frequent

opening and closing of the valves.

Leakage can usually be detected two ways

Sound
Condensate in the drip pan

Tanjung Jati B Training

General Inspection
Boiler

SAFETY VALVES

If leakage is relatively small, it may be due to the

Safety Valve Disc not being properly seated. Using
a long rope attached to the safety valve handle and
manually opening the valve for a brief moment, may
reorient the disc on the seat.

Tanjung Jati B Training

General Inspection
Boiler

Attach Long Rope

Tanjung Jati B Training

General Inspection
Boiler

SAFETY VALVES

If leakage does not stop, there is a chance that the

Safety Valve Disc and or Seat may be damaged or
cut by a small piece of debris or grit.

Pending the opportunity to shutdown the boiler in

order to repair the valve, gagging the valve to prevent
further damage may be possible. Consult your
supervisor.

Tanjung Jati B Training

General Inspection
Boiler

SEAT DISC

Tanjung Jati B Training

General Inspection
Boiler

DISC

SEAT

SEAT

Tanjung Jati B Training

General Inspection
Boiler

SAFETY VALVES

SPECIAL NOTE: If the safety valves have been worked

on by the valve representative, lead seals will be put
on the valve components. If any of the seals are broken,
valve warranty will be void.

Tanjung Jati B Training

General Inspection
Boiler

Tanjung Jati B Training

General Inspection
Boiler

Some items that will be discussed

Steam Drum
Safety Valves
Boiler & Pipe Supports
Expansion Joints
Burner Front
Sootblowers
Air Heater
Fans

Tanjung Jati B Training

General Inspection
Boiler

BOILER & PIPE SUPPORTS

Our attention should focus on hanger assemblies

which indicate their respective HOT and COLD
positions.

Under full boiler load conditions, the hanger should

be at or near the hot position.

Tanjung Jati B Training

General Inspection
Boiler

BOILER & PIPE SUPPORTS

Other hanger assemblies can be checked to see if

they are bearing load by rapping the hanger rod
with a hammer. A solid sound means that the
assembly is carrying load.

Tanjung Jati B Training

General Inspection
Boiler

Some items that will be discussed

Steam Drum
Safety Valves
Boiler & Pipe Supports
Expansion Joints
Burner Front
Sootblowers
Air Heater
Fans

Tanjung Jati B Training

General Inspection
Boiler

EXPANSION JOINTS

Both metal and non-metallic joints can experience

movement in three directions.

Expansion joints are preset in the cold position

and will move as the boiler, boiler flues and ducts
expand.

Tanjung Jati B Training

General Inspection
Boiler

EXPANSION JOINTS

Periodically check expansion joints for any sign

of leakage. Check to see if fabric type joints still
have movement left meaning they are not taut.

Tanjung Jati B Training

General Inspection
Boiler

Some items that will be discussed

Steam Drum
Safety Valves
Boiler & Pipe Supports
Expansion Joints
Burner Front
Sootblowers
Air Heater
Fans

Tanjung Jati B Training

General Inspection
Boiler

BURNER FRONT

Burner fronts should be kept as clean as possible. If

there are signs of oil leakage, this will become very
obvious.

As an operator, visually check the ignitor and coal fires

on a regular basis.

Tanjung Jati B Training

General Inspection
Boiler

BURNER FRONT

Check instruments to see that they are working

properly. Compare relative air flow indications
on the local gauges.

If a gauge is not reading properly, it may be plugged.

The instrument tubing should be blown clean with air.

Be sure not to damage the gauge.

Tanjung Jati B Training

General Inspection
Boiler

Some items that will be discussed

Steam Drum
Safety Valves
Boiler & Pipe Supports
Expansion Joints
Burner Front
Sootblowers
Air Heater
Fans

Tanjung Jati B Training

General Inspection
Boiler

SOOTBLOWERS

Check for any steam leaks around the poppet valve

and piping connections.

Check oil levels and condition of the grease on the

pinion rack.

Tanjung Jati B Training

General Inspection
Boiler

SOOTBLOWERS

SPECIAL NOTE: If a sootblower should become

stuck in the boiler, never turn off the steam since it
acts as a cooling medium.

Use the special retract tool to remove the sootblower

from the boiler.

Tanjung Jati B Training

General Inspection
Boiler

SOOTBLOWERS

Excessive sootblowing can cause boiler tube erosion.

Therefore, when inspecting the boiler, special attention
should be paid to the tube surfaces in the vicinity of the
sootblowers.

Tanjung Jati B Training

General Inspection
Boiler

TYPICAL INSTALLATION

STEAM JET

Tanjung Jati B Training

General Inspection
Boiler

Tanjung Jati B Training

General Inspection
Boiler

Some items that will be discussed

Steam Drum
Safety Valves
Boiler & Pipe Supports
Expansion Joints
Burner Front
Sootblowers
Air Heater
Fans

Tanjung Jati B Training

General Inspection
Boiler

AIR HEATER

When performing routine inspection of the air heater

special attention should be paid the lubrication system.

On the hot side (flue gas in & hot air out) oil leaks
from the guide bearing lubrication system can develop.
Oil can get underneath the lagging and create a fire
hazard.

Always check lubrication oil levels.

Tanjung Jati B Training

General Inspection
Boiler

AIR HEATER

The tri-sector air heater also utilizes sector plates

for its sealing system. If for some reason it is not
working properly or if it is out of adjustment, rubbing
of the seals can occur. As a result, excessive noise
will be apparent and a rotor trip may occur.

If this should happen, the sector plates should be

retracted via the local control station.

Tanjung Jati B Training

General Inspection
Boiler

AIR HEATER

During your routine inspection, always check to see

that the air motor, air isolation valve is open.

Also, check the thermocouple readings on the TTMD

panel display. Air outlet temperature indications
should be close to the same.

Tanjung Jati B Training

General Inspection
Boiler

Some items that will be discussed

Steam Drum
Safety Valves
Boiler & Pipe Supports
Expansion Joints
Burner Front
Sootblowers
Air Heater
Fans

Tanjung Jati B Training

General Inspection
Boiler

FANS

Probably the most typical reason for losing the use

of a fan are its bearings. What can cause bearings to
fail?

Cooling water in the lube oil

Low lube oil level or loss of oil
Using the wrong oil

Tanjung Jati B Training

General Inspection
Boiler

FANS

Routine inspections of the fan and its auxiliary

equipment include

Bearing lube oil level and quality (foaming?)

Bearing lube oil leaks
Bearing lube oil temperature
Bearing vibration (use portable vibration meter)
Lube oil skid pressures and temperatures

Tanjung Jati B Training

General Inspection
Boiler

FANS

Internally, the rotors or blades should be checked for

for signs of any cracks in welds. Cracking is not typical
but inspections should be made.

Tanjung Jati B Training

GENERAL INSPECTION
BOILER
(END)

Tanjung Jati B Training