JSW Energy, CPP#3

SBU2/MM/CL/20/
Doc No:
00
TITLE: Check list for Boiler Annual Shutdown
Date: 01.06.2010
Page: Page 1 of 4

Date start: End: _______________

Description of activity Yes No

1. Opening of all boiler manhole door & peephole door and replacing of
sealing rope.
2. Servicing and replacing of damaged peephole door & manhole door
Ropes and refractory.
3. Inspection of tube /casing sheet in rear arch area/pent house roof and
filling the refractory.
4. Inspection and repair of buckstay, seismic guide & leveler guides
5. Replacement of scanner air and cooling air hoses. (I & C)
6. Furnace air leak test and arrest.
7. Rectification of boiler expansion tramps.
8. Inspection and restoring of boiler refractory (at S-panel, goose neck
area, rear arch area, bottom enclosure area )
9. Checking of insulation & providing insulation if required.(Including
Pent House)
10. Boiler first pass, second pass, wind box and Pent-house cleaning.
11. Inspection of the Pent-house hangers and repair if required.
12. The entire four-corner burner block top insulation and sheet to be
removed and checked for any damage.
13. Installation of Sky climber assembly in the first pass
14. Inspection of water wall tubes, panels, burner panel.
15. Inspection of second pass steam wall, super heater coils, LTSH
upper, middle, lower & bottom coils, economizer lower & upper coils and
check all baffle plates, supports of coil, clamps. Rectify if required.
16. Inspection of Divisional SH coils, platen SH & RH Coils, Final SH &
RH coils. Also inspection of Wall RH front & side walls.
17. Inspection of Roof tubes, Spacer & Positioning Tube.
18. Check all riser tubes and the slide plates.
19. Spacing of LTSH & ECO coils, inspection & providing of coil
shrouding (protection cover ). Inspection of supports & clamps.
20. Inspection of headers inside the pent-house.
Issued & Controlled
Approved by: Control status
by:
S.Ramesh Babu S.Ramesh Babu
CONTROLLED COPY
Section in-charge Section in-charge
 JSW Energy, CPP#3

SBU2/MM/CL/20/
Doc No:
00
TITLE: Check list for Boiler Annual Shutdown
Date: 01.06.2010
Page: Page 2 of 4

21. 100% tube thickness in different areas of boiler such as water wall,
super heater coils, re-heater coils, LTSH, economizer, screen tubes,
spacer tubes etc, and record the same
22. Economizer inlet header all stub joints DP test
23.Insitu metallographic of Headers (All Out let headers of Super heater,
Re heater and Economizer portions).
24.For those areas where the tubes are eroded to 20% of original
thickness, the tube to be replaced as per the standard procedure. The
joint radiography test to be done
25.Inspection of 2nd pass ring header for the mesh and refractory by
providing scaffolding above the hopper.
.26.Inspection of penthouse headers for the insulation & providing
insulation if required.
27.Pent house TOP Roof side refractory providing
28. Boiler drum manhole opening and gasket replacement.
29. Drum internal inspection.
30. DP test of phosphate dosing line, hydrazine dosing line, EBD & CBD
lines.
31. Removal of all the boiler internals, cleaning , inspection and re-
assembly
32. Inspection of LRSB & WB sleeves.
33. Inspection of drum level gauges.
34. Inspection of Drum insulation if required provide the insulation
35. Inspection of ash accumulation in side the wall re heater out let
header By cut opening of skin Casing.
36. Boiler hydro test
37. Coal burner inspection and rectify the damaged burners. And
servicing of all coal burners.
38.Inspection of secondary air nozzles and replacing the damaged ones.
39.Inspection of HFO oil gun Diffuser cone assembly
40.Inspection of End air nozzles and OFA.
41.Inspection of LDO and HFO oil burner assemblys and replacing of
associated hoses, pipe lines as required.
42. All 4 corners Burner tilting inspection, operation, alignment, ensuring
Issued & Controlled
Approved by: Control status
by:
S.Ramesh Babu S.Ramesh Babu
CONTROLLED COPY
Section in-charge Section in-charge
 JSW Energy, CPP#3

SBU2/MM/CL/20/
Doc No:
00
TITLE: Check list for Boiler Annual Shutdown
Date: 01.06.2010
Page: Page 3 of 4

burner tilt zero position and 20 deg position for coal burners and 30
deg for all others Except OFA from both out side and inside the furnace
with bevel protractor, ensuring all burner tilt tie rods are intact. Inspection
of reach rod, bell cranks etc and rectification if required.
43.SADC inspections, operation, alignment, repair/replace of damaged
parts. If required servicing of SADC Cylinders.
44. Removal of insulation at the surroundings of wind box and other
doubtful areas and leak identifying in air leak test and welding the same.
45. Inspection of coal pipe bends.

Specific observations if any (Sl No. wise)

Issued & Controlled

Approved by: Control status
by:
S.Ramesh Babu S.Ramesh Babu
CONTROLLED COPY
Section in-charge Section in-charge
 JSW Energy, CPP#3

SBU2/MM/CL/20/
Doc No:
00
TITLE: Check list for Boiler Annual Shutdown
Date: 01.06.2010
Page: Page 4 of 4

Issued & Controlled

Approved by: Control status
by:
S.Ramesh Babu S.Ramesh Babu
CONTROLLED COPY
Section in-charge Section in-charge