1/31/2017 BoilerSurvey|MarineStudy

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BoilerSurvey
PostedonNovember3,2014byMarineStudy

BOILERSURVEY

BoilerInspection

Introduction

Boilersareinspectedtomaintaintheregulatoryrequirement.Regularinternalandexternalexaminationduring
suchsurveyconstitutesthepreventivemaintenancescheduletheboilergoesthroughtohaveasafeworking
condition.

Interval:

Boilersrequiretobesurveyedat2yearintervalsuntiltheyare8yearsold,thereaftertheybecomeduefor
surveyannually.

Procedures
Planning

1.DiscusswithMasterandChiefEngineertoconfirmtimeavailable,manpowerandtimerequiredandsteam
requirementfornextport.
2.Checksbeforeshuttingdownboiler:
3.Sufficientspares(joints,packing,gaugeglass,etc)
4.Pastreportsandmanualforspecialattentionneedtobetakecare
5.SpecialToolsrequired
6.Meetingandbriefwithallengineersinvolved
7.Markallvalves,safetyvalvesettingandspigotclearance

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Beforeshuttingdownboiler

1.InformChiefengineer
2.Informdutydeckofficer
3.TopupDOservicetank
4.ChangeoverM/E,A/EandboilertoDieseloil
5.Stopallpurifier
6.Shutallheatingandtracingsteamvalve
7.Sootblowtheboiler

ShuttingdownBoiler

1.Changeovertomanualfiring
2.Stopfiring
3.Purgeboilerfor5minutes
4.Shutmainsteamstopvalve
5.Switchoffpower,offthecircuitbreakerandremovefusesforFDfan,FOpumps,feedpumpsandcontrol
panel.
6.Putanoticeonthecircuitbreakermentionedabove
7.Shutallfuelvalveandatomizingvalveandlocktheminshutposition,blankthelineifnecessary
8.Allowboilertocooldownslowly
9.Scumblowdownfollowbybottomblowdownwhentheboilercooled

Openairventwhenboilerpressuredropuntil2bartopreventvacuumformation
Furthercoolingofboiler
Preparetoopentopmanholedoorwhenboileriscooledandatatmosphericpressure
Slackenthedognutandsecuremanholewithrope
Knockmanholedoorgentlywithlongstick.Donotopenfullybecausehotsteamorwatermightgushout.
Openfullwhenissafe
Allowfurthercoolingofboilerbeforeopenthebottommanholedoor.Thisistopreventthermalshock
Confirmnolargequantitiesofhotwaterlyinginthebottom
Openthebottommanholedoorwiththesameprecautionaswiththetopmanholedoor
Openthefurnacedoorslowly
Ventilatetheboilerbothwaterandfiresidefor1224hours
Enclosespaceentrypermitobtained
CheckOxygen,flammablegasandtoxicgascontent
Preparetoentry

Preparationforentry

1.Preparesafetytorchandsafetyhandlamp
2.Investigatefromoutsidemakesureitisclearfromobstructionbeforeenteringboiler
3.Oxygenanalyzeriscarrywiththepersonenteredboiler
4.Personnelenteringmustwearallsafetygears

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5.Clearpocketcontentsandtoolstobecarriedinabagandaccounted
6.Aresponsibleengineertobestandbyoutsidewithclearemergencyorder
7.Keepbreathingapparatusready
8.Remaincommunication
9.Ensureproperlightingatalltime

BoilerInspection

1.Thoroughlycleanedbeforeboilerissurveyed
2.Wirebrushandhosedownmaybesufficienttoprepareforsurveyinwellmaintainedboiler
3.Chippingoffscaleisnecessary
4.Iftracesofoilarefoundinboiler,chemicalmeansmayhavetobeadoptedtoremovethem

Routeofinspection

i.GasSide

1.Exteriorofdrumsforsignsoftuberoll,leakage,corrosion,sooterosionandoverheating
2.Conditionofoutsidedruminsulation
3.Drumsealsforsignofairleakage
4.Inspectdrumsupportforcrackandexpansionclearance
5.Allblowdownconnectionsforexpansionandflexibilityofsupport
6.Allpipingandvalveforleaks
7.Waterwalltubesandfinsforcrack
8.Exteriorofalltubesforcorrosion,carbonbuildup,erosion,blistersandsagging
9.Tubesnearsootblowersforsteamimpingement
10.Conditionofrefractory
11.Aroundburnerassembly,refractoryandaccumulationofsootorcarbon
12.Sootblowerfordistortion,wornbearings,rubbingoftubes,conditionofnozzles,cracks,freedomofmovement
andeffectivelubrication

ii.Waterside

1.Steamdrumforcorrosionscalingandpitting
2.Manholeseatsandsurface
3.Conditionofallfee,chemicalfeed,blowdownlinesandinsidepressurepartsforchoking,securityandleaks
4.Tubesforcorrosion,excessivedeposits,flarecrackingandpitting
5.Handholeplatesandstudthreads

iii.SafetyValve

1.Conditionofvalveinternalpartsforsignsofcorrosion,gallingandwear
2.Checkforpitting,crack,resiliencyandconditionofsprings
3.Checkspindleforstraightnessandadjustingringthreadforfreedomofmovement
4.Checkdischargeanddrainpiping

iv.Checkdamperstoensurethatlinkagearesecuredandwellgreased

v.Conditionofburners,swirlerandairregister

vi.Windboxdampersandvanesforsignofcorrosionanderosion

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vii.Checkconditionandoperationofallvalve

viii.Checkfeedwatercontrollerandcontrolvalveconnectionlinesandensureproperfunctioning

ix.Examinethefoundationandbracingboltsofboilerforcorrosion,frettingandrusting

Closing

1.Inspectinternalsurfacetoensuretheyareclean
2.Countercheckalltoolsareoutfromboiler
3.Allopeningofthemountingarecleanedproperly
4.Mountingstobefixedbackwithnewsetofgasket/joint
5.Replacetheheaderhandholeandthebottommanholedoor
6.Operateallmountingvalvestoensuretheyworkfreelyandleaveallvalvesincloseposition
7.Replacetopmanholedoor
8.Sootblowerarecorrectlyfitted
9.Aircontroldampersmovefreelyfortheirfulltravel

Preparationflashingup:

Opengaugeglasssteamandwatercocksandshutdraincock
Openvent,alarmandpressuregaugeconnectionvalve
Shutalldrainvalve
Switchonpowerforcontrolpanel,feedpump,FDfanandFOpump
Fillboilerwithhotdistilledtreatedwater
Filluntilwaterlevelbelownormallevel
Checkcontrolairisavailable

FlashingUp

1.StartFDfanandpurgeboilerfor5minutes
2.StartFOpumpandcheckallparameters
3.Fireboilerwithminimumfiringratio
4.Continuefiringintermittentlye.g.1min.fire,stop10min.for1sthour,2minfire,stop10min.for2ndhourandso
on.
5.Asboilerheatsup,waterlevelwillrisetonormallevel,topupifnecessary
6.Continuefireuntilacontinuousstreamofsteamcomesoutfromairvent
7.Shutairvent
8.Blowthroughgaugeglasswhenboilerpressureraised
9.Openvalvetoremotelevelindicator

At7bar,allsecuringbutstoberetighten
Opensteamlinedrainstodrainoffcondensate

Startingtheboilerforanormaloperation:

1.Warmupthesteamline
2.Gag1safetyvalve,raisethesteampressureslowlyandchecksafetyvalveoperationandifneedadjustit.
3.Repeattheprocedureforothersafetyvalve
4.Ensurenocondensateatthedrainline
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5.Crackopenmainsteamstopvalve,slowlyopenuntilitsfullopen
6.Keepfiringassteadyaspossible
7.CheckallsafetycutoutsandalarmsbeforeputtingboileronAuto
8.Finalroundcheckonboiler
9.Starttanksandtracingsteamheating
10.Opensteamtoallheaters
11.Startallpurifier
12.ChangeoverfromDOtoHOforboilerandGenerator

M/Echangeoverduringdeparture

EGESafetyvalve

1.C/Etosetthesafetyvalvewhentheshipisatsea
2.Reporttosurveyorinwritingtoconfirmsafetyvalveoperation

WrittenbyMarineStudy

ForMaritimeEducationandKnowledge

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