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BOILER INSPECTION
Boiler-Takuma N1500 P
3. OBJECTIVE
The inspection consisted of internal and external exams of the Boiler and measurement of the pressure parts thickness
in order to evaluate the real physical conditions of the Boiler.
4. PERIOD OF INSPECTIONS
Beginning: 26/04/2010 End: 04/05/2010
5. ACCOMPLISHED INSPECTION
Operational evaluation of the boiler was accomplished.
7. DESCRIPTION OF SERVICES
ANALYSIS OF THE TECHNICAL DOCUMENTATION.
Handbook
Manual of Operation
8. ACCOMPLISHED INSPECTIONS
MEASUREMENT OF THICKNESS )
Parts subject to the internal Pressure (Drum/Tubes/Heater)
Procedures
PRO-DPI-004 - Thickness Measurement by Ultrasonic sound waves
PRO-DPI-054 - Hydrostatic Test
PRO-DPI-058 - Inspection of Water Tube Boiler
10. RESULTS
10.1.1. Handbook
- Code of the project and year of edition
- Specification of the materials
- Procedures used in the production, assembly, final inspection and determination of MWP
- Group of drawings
- Functional characteristics
- Data of safety's devices
- Year of production
Opinion There is The handbook of the Boiler with all the necessary information that approves the integrity of the
: Boiler and helps with the maintenance planning and repairs.
Opinion There is the Manual of Instructions with all the needed technical information and it is necessary that all
: the Boiler operators know the routines of this document.
Opinion We recommended the system of water treatment to be reviewed by a specialist company, since
: nowadays there is a more efficient technology. GE WATER and NALCO companies are leaders in this
1.1.1. Outlying
a) Piping and Water Feeding Pump
Piping presents severe corrosion committing the Water feeding pump should be revised before entering in
structural integrity of the component operation.
b)
Opinion: All outlying for control and operation of the Boiler should be tested, maintained and substituted when
necessary.
Opinion Visually, the structure of the boiler presents satisfactory result for operation of the boiler.
:
Right side of the furnace in good state Left side of the furnace should be repaired
Level Visor should be tested and maintained Magnetic Transmitter of Level should be tested and maintained
before the operation of the boiler. before the operation of the boiler.
Opinion: All control and operational components of the Boiler should be tested and maintained.
c) Thermal Isolation
Exit of gases and left side of the Boiler show damaged Roof of the boiler furnace and tube risers show damaged
isolation. isolation.
Opinion Visually, the isolation of the boiler is damaged in several points. Repairs should be accomplished to avoid
: accidents with the operators and for a better thermal efficiency of the Boiler.
a) Oil Reservoir
Visually, the reservoirs present a satisfactory result; when Regulators of oil line flow should be maintained and
possible, they should be inspected internally for leak installed.
verification.
b) Oil Pumps
Oil Heaters should be cleaned and inspected Oil Heaters should be cleaned and inspected
Opinion Based on the equipments Report, the cleaning of the heater internal parts and a visual inspection are
: necessary to verify the condition of the equipment and the need of the No Destructive Test.
d) Burners
Opinion All the internal components of the Burners should be disassembled: valves, o rings, holes. They should
: be inspected and tested on bench.
Manufacturer : TAKUMA
Boiler/ Model : N 1500P
Year of production : 1982
Registration number : N 2625
Steam production : 100.000 kg/h
Pressure of Operation : 30,0 kgf/cm
Max Working Pressure : 36,0 kgf/cm
Pressure of Hydrostatic Test : 54,0 kgf/cm
Heating surface : 1158m
Temperature of the overheated steam : 380C
Edition / Addenda of the code : 1982
Project code : ASME I
Addressee : Misan State Sugar Enterprise
Opinion All of the flanged safety valves installed in the Boiler should be dismounted, inspected and tested on
: bench and, regarding the welded valves, calibrated.
Visually, the panel and their instruments present good Every instrument of the Boiler should be tested before the
conservation state. Boiler enters in operation.
Opinion All instruments of the Boiler should be dismounted, inspected, tested and calibrated.
:
There are several tubes of the Bank disabled due to a flaw Visually, an excessive accumulation of a white colored
during the operation of the Boiler. incrustation was observed.
Opinion: All of the internal elements should be dismounted and cleaned to guarantee the efficiency and the
:
operation of the equipment; it is advisable to accomplish the Hydrocleaning of the Boiler internal parts.
Visually, an excessive accumulation of white colored There are several tubes of the Bank disabled due to a
incrustation was observed.. flaw during the operation of the Boiler.
Heater Tube was removed for substitution of the Boiler External side of the Drum Water where the Bank tubes
Bank tubes. were being substituted.
Opinion Visually, an excessive accumulation of white colored incrustation was observed. Analysis should be
: accomplished for correction of the water treatment of the Boiler.
The initiated repairs in the Boiler should be finished.
10.3.3. Superheater
Table 3- Superheater (Measurement of Thickness mm)
Point n 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
A x x x x x x x x x x x x x x x
B x x x x x x x x x x x x x x x
Point n 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
A x x x x x x x x x x x x x x x
B x x x x x x x x x x x x x x x
Legend:
A= Straight C= Straight E= Straight G= Straight
B= Curved D= Curved F= Curved H= Curved
Ext. 50,8 mm
a)
Opinion Visually, relevant deformations in the component were not observed. An access to the tubes should be
: provided for thickness measurement.
Point n 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
A 3,96 4,17 4,49 4,42 3,96 4,33 4,37 4,29 4,30 4,29 4,00 4,23 3,84 3,99 4,06
B x x x x x x x x x x x x x x x
Point n 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
A x x x x x x x x x x x x x x x
B x x x x x x x x x x x x x x x
Legend:
A= Straight C= Straight E= Straight G= Straight
B= Curved D= Curved F= Curved H= Curved
Ext. 50, 8 mm
Area where Boiler Bank tubes were substituted. Closing row of Boiler Bank should be reconstituted (17
Opinion As commented in the subtitle 10.4.1 of this report, the tubes of the Boiler Bank should be
: Hydrocleaned; the structural condition of these tubes should be evaluated and subsequently repaired.
The initiated repairs in the Boiler should be finished. The measurement of thickness presented
satisfactory results.
Inspection was accomplished in areas that suffer wear and Measurement was accomplished in 100% of the
tear by abrasion and erosion.. prepared tubes. Samples from15 points per Furnace wall
were collected for the report.
Tube in the center of the front wall is disabled; a needed Visually, the furnace presents good conservation state,
repair should be accomplished. the accomplishment of routine maintenance is necessary.
Opinion The initiated repairs in the Boiler should be finished, measurement of thickness presented satisfactory
: results.
At the Furnaces Left Side, the substitution of the wall Area where approximately 15 tubes were substituted.
tubes was observed and they were welded directly to the
collector. The code ASME informs the need of thermal
treatment for thicknesses larger than 19,00 mm. The
Header is 25,4 mm.
Furnaces Left Side area, where repair should be Furnaces Left Side area, where repairs in the Boiler
accomplished in 12 (Twelve) tubes 76, 2 with should be concluded in 10 (ten) tubes 76, 2 with
approximately 500, 0 mm and 1300, 0 mm length. approximately 2800, 0 mm length.
Opinion Planning should be accomplished for the execution of repairs and thermal treatment, where applicable.
:
The initiated repairs in the Boiler should be finished, measurement of thickness presented satisfactory
results.
a) Economizer
Points of the Economizers Left side, where thickness Points of the Economizers Right side, where thickness
was measured. was measured.
Tube disabled during operation of the Boiler. Necessary Welds accomplished in the tubes should be
repair should be accomplished. hydrostatically tested for approval.
Opinion The initiated repairs in the Boiler should be finished; measurement of thickness presented satisfactory
: results.
The welds accomplished in the Boiler should be hydrostatically tested for approval.
Fan internal parts should be disassembled, cleaned, Reducer and Turbine should be inspected and a
inspected and balanced.. necessary maintenance should be done.
Opinion: Equipments should be maintained and tested before setting the Boiler in operation.
:
Fan internal parts should be disassembled, cleaned, Electric motor should be inspected and necessary
inspected and balanced. maintenance should be done before reinstallation.
Fan internal parts should be disassembled, cleaned, Reducer and Turbine should be inspected and necessary
inspected and balanced. maintenance should be done.
Opinion Equipments should be maintained and tested before setting the Boiler in operation.
:
a) Header of Economizer
Area where the measurement of thickness was The repair was not foreseen in the project. It should be
accomplished. approved after Hydrostatic test.
Opinion The initiated repairs in the Boiler should be finished, measurement of thickness presented satisfactory
: results.
The welds accomplished in the Boiler should be Hydrostatically tested for approval.
Opinion The hydrostatic test should be accomplished after the conclusion of the Boilers maintenance with the
: value of 1,5 x MWP for detection of possible flaws in the Boilers tubes, where the meticulous inspection
of the equipment was performed.
The welds accomplished in the Boiler should be Hydrostatically tested to be approved.
13. CONCLUSION
1.1. The Boiler should be submitted to welding interventions and expansion of mandrel. These services should be
accomplished by the Qualified Supplier. See subject 10.4.4 and 10.4.5
1.2. The recommendations mentioned in the item 12 of this report should be totally assisted.
1.3. Obs. The minimum wall thicknesses of the pressure parts are satisfactory and approved for the defined operation
conditions in the project adopted for construction of the equipment.