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Boiler Overhaul

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steam boiler Industri makanan

Boiler Overhaul

Boiler Overhaul.

Boiler overhaul is done every 15 months to connect CF (Certificate of Fittness) or + 3 months + 3 months (approved) 

Step2

1)Lower firing, stop boiler operation and cooling down
2)Create boiler system isolation
3Open man hole boiler
4)Perform boiler pre-inspection (internal)
5)If there are defects such as cracks, it must be repaired first
6)Create mechanical cleaning on surfaces, tubes and furnaces
7)Final inspection (internal)
8)DOSH inspection
9)Box-up
10)Filling the boiler with feed water and leak check
11)If DOSH wants a Hydro test, blind all flanges and join the HT test procedure
12)Flushing all boiler water when finished
13)Filling boilers and chemical dosing of Ammonia and Hydrazine
14)Start-up boilers
15)Recommissioning and safeguarding tests (PSV, Level switches)

Boiler Baffles

Q. What is the boiler baffles?

A. The flow of the combustion gas over the banks of boiler tubes is controlled by what a called baffle.

Q. What factors does baffle arrangement depends?
A.           1. Allowable draft (draught) loss
               2. The layout the boiler heating surface and its dimension
               3. Gas out position
               4. Fuel
               5. Fuel burning equipment and operating parameter
               6. Baffles supporting device

Q. What factors should be considered in designing a baffles
A. The baffle design should be such that it
              1.Ensures best distribution of heating surface with respect to gaseous product of combustion
              2. Ensures proper flue gas velocity
              3.Maintain cross flow of flue gas pass the boiler tubes
              4. Deposit flyash and dust where is it accessible for easy removal
              5. Eliminates dead pockets
              6. Avoids high draft (draught) loss

Blowdown Valve

Bottom blow down valves: They provide a means for removing solid particulates that condense and lay on the bottom of a boiler. As the name implies, this valve is usually located directly on the bottom of the boiler, and is occasionally opened to use the pressure in the boiler to push these particulates out. 

Surface blow down line: It provides a means for removing foam or other lightweight non- condensible substances that tend to float on top of the water inside the boiler.

Boiler Explosion

Letupan yang berlaku didalam Furnace
Minor Explosion dipanggil sbg Puff, Flareback or fire blowback.Biasanya disebabkan oleh:
– pengumpulan gas yang tidak terbakar (unburn fuel) didalam furnace
– Air/fuel ration in a explosive mixture
– Pembakaran yang tak sempurna
– ignition timing failure
– insufficiency purging process
– Fuel supply and control not in proper condition
– Loss of furnace draftKerosakan akibat daripada Furnace Explosion
Dinding boiler retak, mengelembong dan runtuh
Tube dan tube plate retak, longgar akibat dari gegaran
kerosakan pada plate baffle
kerosakan teruk seperti boiler explosion, drum sagging dan kerosakan boiler structure

Langkah2 asas bagi mencegah Furnace explosion:
Buat pemeriksaan boiler operasi secara berkala
Sekiranya burner stop tiba-tiba, pastikan fuel supply diberhentikan dan buat pemeriksaan dengan teliti
Pastikan burner dan peralatan yg berkaitan dgn burner sentiasa bersih dan memuaskan(working satisfactory)
Periksa interlock system secara berkala sekiranya boiler mengunakan induce dan force draft fan
Pastikan suhu dan tekanan air preheater, drying air dan fuel air mengikut suhu standard yg diperlukan
Jangan biarkan Pembakaran yg tak seimbang berterusan didalam furnace
Purge furnace dengan sempurna sebelum boiler firing

Boiler Tubes Name

Generating Tube/Riser

-Direct tube to the flue gas

-Material normally medium carbon steel
-OD size 2~3 inches and thickness 3.2 ~4.5 mm 
Downcomer tube
-Not direct to the flue gas
-OD > 6 in 
Superheater tube
– To add heat to the steam without raising the pressure of the steam
-Material High Carbon steel
-Generate superheated steam 
Distributing tube/water injection
-to distribute water into drum – below LWL 
Economizer tube
-To increase temp feed water before it enters to the boiler drum and reduce flue gas temp
-after the last path of flue gas
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