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Planning 

1. 1. 1. 1. 1. Planning to be done and discuss with technical super.
            2. Risk assessment to be done
            3. Permit to work obtain
            4. Check for necessary tools and spares
            5. Check manual for special instruction and check past records
            6. Next port steam consumption obtain
            7. Personal involve to be briefed

 

Shutting down for survey

• Inform duty officer 
• Change over me, ae and boiler to DO
• Top up do service tank, stop all purifier. 
• Stop tank heating and steam tracing
• Changeover boiler from auto to manual.
• Stop the boiler and purge for 3-5min
• Switch off power on panel and switch off circuit breaker for fo pump and feed water pump
• Put up do not start
• Shut min steam stop valve and shut fuel valve and feed water valve
• Let the boiler cool down
• When boiler pressure ~ 4 bar, carry out blow down
• When boiler pressure ~ 2 bar. Open vent
• Let the boiler cool down
• When sufficiently cooled at atmospheric pressure, open top manhole door with all safety precaution.
• Knock gently as may contain how water/ steam
• When nothing coming out, open manhole with support of rope
• Open bottom hand hole door 
• Ventilate for few hours.

Prepare for entry 

1. Wear proper PPE like safety shoes, helmet , hand gloves
2. Enclose space entry permit to be obtain
3. Keep an inventory of tools taken inside
4. Keep one responsible engineer standby outside with clear emergency orders
5. Keep emergency breathing apparatus standby
6. Ensure proper lighting of ventilation
7. Carry a gas detector, manually calibrate it in open atmospheric condition
8. Ensure proper communication

 

Boilers are to be surveyed twice in a 5 year period. And are subjected to an external inspection as part of the annual survey. 

• Boilers are examined internally and externally within a period of 2.5 years. 
• The boiler is first emptied and suitably prepared for the examination. The water-steam side and fire side are to be cleaned and cleared of soot. Where necessary, the external surfaces are to be made accessible for inspection by removing insulation.
• Boiler mounting and safety valves are to be examined at each survey and opened as considered necessary by surveyor. Proper operation of safety valves to be confirmed at each survey also boiler safety valves’ easing gear to be examined and tested satisfactory.
• Parts requiring particular attention:

• Foundation: boiler supports, bolting and securing arrangements to be examined. 

E.g. fixed and sliding seating chocks, rolling stays.

• Furnace: – check for distortion; mainly due to overheating from excessive 

scaling and thermal stresses.

• Flame impingement, across the path of the flame
• Check the condition of refractory.
• Furnace bottom is free of oil

• Shell, tube plates and tubes:

–       check for deformation, corrosion wastage, cracks etc.

• Inlet tube ends for corrosion and erosion
• Region in way of normal water range inspected for cavitations, pitting etc.
• Cracks at welding in way of valve openings
• Wastage in way of manhole and handhole flanges

• All boiler mountings:

• Soot blowers
• Water level gauge glass including cock valves
• Main steam stop valve
• Air vent valve
• Sampling valve
• Feed stop and check valve
• Scum valve
• Blowdown valve
• Manhole cover
• Pressure gauge for calibration 

• Hydraulic Test:

• To be carried out if alteration or repairs have been carried out on highly stressed parts, major tube renewal, shell plating renewal or when requested at the discretion of the surveyor.

• External:

• Upon completion of internal survey the boiler has to be examined under steam with the fuel burners and safety valves checked under working conditions

• Alarm Test:

• High and low water levels
• Low-low water level; automatic shutdown with alarm
• Force draft fan or flame failure-automatic shutdown with alarm

• Log Book: A review of boiler operation and feed water treatment records.
• Manual Emergency Shutdown:

• Boiler force draft fan and fuel oil service pumps are to be fitted with remote means of control situated outside the space in which they are located so that they can be stopped in the event of fire.

What inspection to be carried out on Boiler water side and smoke side.

• Smoke side: – check for distortion; mainly due to overheating from excessive scaling and thermal stresses.
• Flame impingement, across the path of the flame
• Check the condition of refractory.
• Furnace bottom is free of oil

• Water side:

–     check for deformation, corrosion wastage, cracks etc.

• Inlet tube ends for corrosion and erosion
• Region in way of normal water range inspected for cavitations, pitting etc.
• Cracks at welding in way of valve openings
• Wastage in way of manhole and handhole flanges

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