IDEA s 26th Annual Campus Energy Conference Optimizing Boiler Inspections
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1 Optimizing Boiler Inspections Joe Maciejczyk, P. E. IDEA Campus
2 Case Study Process and Heating steam user One PC Boiler, 3 Natural Gas Evaluate NG boilers for continued operation or replacement Boiler Inspection/SLIDE 2
3 Scope Steam Drum Tubing Refractory Burner Ductwork Flue Combustion Air Fan Mud Drums Boiler Inspection/SLIDE 3
4 Discussion Exclusions Stacks Deaerator/DA Storage (system) Boiler External Piping Feedwater Boiler Inspection/SLIDE 4
5 CE A-Style, Saturated Steam Packaged Boiler 1972 start-up Oil>Gas Hours and number of starts unknown 250psig, 121,000 pph No Economizer or Superheater Boiler Inspection/SLIDE 5
6 Typical Inspections Yearly AI inspection Water treatment vendor Operator daily/weekly inspections Exception inspections Boiler Inspection/SLIDE 6
7 Boiler Inspection/SLIDE 7
8 Scope Steam Drum Tubing Refractory Burner Ductwork Flue Combustion Air Fan Mud Drums Boiler Inspection/SLIDE 8
9 Steam Drum Pitting damage at the water line (layup and operating). Attachment welds and bolts on hangers & brackets supporting feedwater piping, baffle panels and primary & dryer screens. Inspection of the feedwater piping and internal distribution system. Drain piping connection to primary screen box. Gauge glass pipe penetrations to insure bore is open. Tube ligament penetrations surface NDE Man-way attachment for cracking or signs of leakage. Surface and volumetric NDE of head-to-shell and longitudinal welds. Evidence of leaking at the man-way seals. Video scope inspection of tube internals (%) for attack and/or wastage. Boiler Inspection/SLIDE 9
10 Phased Array Ultrasonic Boiler Inspection/SLIDE 10
11 Welds located with eddy current or etching Boiler Inspection/SLIDE 11
12 Scope Steam Drum Tubing Refractory Burner Ductwork Flue Combustion Air Fan Mud Drums Boiler Inspection/SLIDE 12
13 Inspect tube external surfaces for evidence of pitting, blistering, burning, bulging or swelling. Wall tube alignment. Tube UTT for general wastage Integrity of any hangers and supports. Refractory deficiencies. Perform Wet Florescent Magnetic Particle (WFMT) inspection of wide membrane at burner throats and other nested area (if applicable) for crack detection to insure no potential membrane cracking extends into the tube walls. Perform inspection of outer surface of accessible areas of the lower drums including tube stubs for corrosion damage. UT readings of Lower drum tube stubs (boiler bank tubes) if wastage is detected. Morphology of pitting if detected. Boiler Inspection/SLIDE 13
14 Tube thickness Use good nomenclature and have a plan that is easily repeatable. Boiler Inspection/SLIDE 14
15 Scope Steam Drum Tubing Refractory Burner Ductwork Flue Combustion Air Fan Mud Drums Boiler Inspection/SLIDE 15
16 Scope Steam Drum Tubing Refractory Burner Ductwork Flue Combustion Air Fan Mud Drums Boiler Inspection/SLIDE 16
17 Ductwork and Flue External casing and support inspection for any signs of distortion or damage. Inspection of expansion joints internally and externally. Visual (VT) internal inspection to verify integrity of the gas passages to the stack NDE of internals if areas of wastage or other defects are found visually Boiler Inspection/SLIDE 17
18 Scope Steam Drum Tubing Refractory Burner Ductwork Flue Combustion Air Fan Mud Drums Boiler Inspection/SLIDE 18
19 Scope Steam Drum Tubing Refractory Burner Ductwork Flue Combustion Air Fan Mud Drums Boiler Inspection/SLIDE 19
20 Joe Maciejczyk, PE Structural Integrity Associates Cell Austin Metallurgical lab Chicago Turbine inspection group State College, PA - NDE R&D, Guided Wave Boiler Inspection/SLIDE 20
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