WELCOME

MAINTENANCE OF WATER WALLS, ECO,SH AND RH COILS

MAINTENANCE PLANNING
Maintenance Planning is called nerve center Maintenance Planning enables to carryout maintenance activities at the appropriate time, method and at minimum cost.

Maintenance planning is deciding in advance about

Jobs Material Tools Machines Labour Time required Sequence

OBJECTIVIES
To forecast the method To estimate the works in advance To procure spares and consumables To fix an agency to carryout the works To prepare schedules To control labour forces To simplify the activities To minimize the inventory

Maintenance Planning

Lowers the cost of overhaul Lowers maintenance time Helps to utilize the overhaul period effectively It eases the problems of purchase of critical spares. It plays a vital role in achieving higher production. Prevents accidents. Helps to solve complicated problems. Helps to utilize the manpower and machines effectively.

HOW TO DECIDE OVERHAUL PERIOD

Monsoon season ( July to Dec ) Previous overhaul period Furnace conditions Operational parameter Spares position Major problems in Boiler, TG etc. Which quarter to be utilized for O/H

AGENCY FOR O/H

Past experience License holders Fixing pre-qualification requirements Fixing responsibility Safety to be followed Statutory requirements Minimum wages, PF etc. CIB approval, IBR approval Inspection

Criteria for maintenance planning

Commitment to grid Periodicity between overhauls Fuel availability Engineering factors related Rolling plan for five years Target by CEA Spares availability Cost optimization Modernization / up gradation

Types of maintenance
Preventive maintenance as per schedule Break down maintenance Short shut downs Major overhauls RLA / LEP / R & M

Pressure Parts & Furnace

Coil cleaning Furnace cleaning Thickness survey Header inspection Inspection of De-superheaters Window normalizing Sample cutting Fixing of sleeves and baffles

PREVENTIVE MAINTENANCE
Physical Inspection During Cleaning Overheating Clamping Integrity of the Coils Erosion Pattern Condition of Sleeves / Baffles

THICKNESS SURVEY
Cleaning of Coils Measuring of Thickness Around 2500 to 3000 Spots Per Boiler Preparation of Report Comparing the Results With Previous Values

REMEDIAL ACTIONS
Analysis of erosion Planning for procuring of spares & consumables Planning for execution Thickness reduction up to 20%, put sleeves More than 40% replacement

Thickness Reduction -Causes

Ash erosion Soot blowers Due to failure of adjacent tubes Corrosion Rubbing with clamps / other coils Overheating/ bulging Oxidation

SAMPLE CUTTING
Presence of micro cracks Fe3 O4 coating. Pitting if any Internal / external corrosion Physical dimensions

BREAK DOWN MAINTENANCE

INDICATIONS - Noise at local - More make up - FG temperature variations - Furnace vacuum - ID fan loading - Drum level - Difference between SF / WF

Follow up of previous history

No. of outages Location of failure Nature of the failure Probable causes Remedial actions taken Performance

IDENTIFICATION
Local inspection Shutting down of boiler Start one ID fan Physical inspection at 10 ksc Draining clearance Forced cooling Assess the damage Analyze the cause for the failure Take prevent actions

COILS
Reasons for punctures Erosion Weld defects Rubbing Corrosion Overheating Faulty material Steam soot blowers

WATER WALLS
Erosion Mechanical impact Weld defects Starvation Blockage More bends Faulty materials Soot blowers

REPLACEMENT
Sufficient cooling Removal of insulation Removal of WSB if required Removal of refractory if required Identification of damaged tube Level cutting ,edge preparation Spool piece preparation Positioning , alignment Welding welding of clamps / fin

GENERAL RULES FOR WELDING REPAIRS

Carefully cut away fins and clamps to have enough access for chamfering. Remove the damage tube. Clean the tube ends to bright metal inside and outside for at least an inch. Remove all scales and deposits Tube edges shall be squared and chamfered. Minimum length of the tube should be 150mm.

Correct fit up shall be given Maintain correct root gap. Both joints shall be tack welded. First pass shall be done by TIG welding. Complete the root, inter and final pass welding. Use correct polarity for TIG and SMAW. Weld back fins and clamps.

MAJOR OVERHAUL
Follow up of previous history No. of outages Location of failure Nature of the failure Probable causes Remedial actions taken Performance

Furnace & coil cleaning

Soot blowers are to be operated at periodic intervals During overhaul coils are to be cleaned either by air, water or manual. Acid cleaning if the internal deposits are more.

VISUAL INSPECTION
Bulging Erosion Corrosion Bowing Overheating Loss of integrity Pitting Fouling Alignment Support system Sleeves & Baffles

DIMENSIONAL ANALYSIS
Thickness survey OD measurement Oxide scale measurement

INSPECTION OF ORIFICE
At Eco inlet, 8 mm orifice is provided in each coil. In random ID of the orifice is to be checked for any blockage/ enlargement

SAMPLE CUTTING
Cutting of sample tubes at various locations to assess the internal conditions for following checks. Surface cracks, pitting, erosion, deposits, chemical analysis and microstructure analysis.

Fiberoscopic inspection
To inspect the internal conditions of the components at intricate locations for accumulation of debris, cracks, blockage, erosion, pitting and integrity.

REPLICA
To find out the pattern of microstructure to assess the degradation. HARDNESS MEASUREMENT Weld HAZ Parent metal

DESUPERHEATERS
VISUAL INSPECTION Bulging, overheating, bowing, support system, orientation, conditions of NRV, filter and branch lines are to be checked. Dimensional check Measurements of OD and thickness checks are to be carried out in random.

 Fiberoscopic inspection To assess the internal conditions of DESHS for Shifting of thermal sleeve Cracking of thermal sleeve Missing / tilting / blockage of nozzles

Fiberoscopic inspection
To assess the internal conditions of DESHS for Shifting of thermal sleeve Cracking of thermal sleeve Missing / tilting / blockage of nozzles

INSPECTION OF SUPPORTS
Hanger support readings Boiler expansion readings Buck stay movements Functioning of boiler guides Roof supports are to be checked both in hot and cold conditions

Manholes
Rectify door clamps and hinges Replace sealing rope and bricks Provide refractory on doors Ensure perfect closing

Ways to protect boiler pressure parts

Metal temperature should be kept with in permissible limits. Raising and lowering of steam parameters should be as per recommended pattern. Tube leakage shall be attended at the earliest. Maintain chemical regime properly. Maintain drum level as recommended

 Do not by pass drum level and steam temperature protections. DESHs shall be maintained above saturation temperature of spray water. FGT Temperature between left and right side should be kept minimum. Use defect free injection valves. Avoid entry of foreign materials in to the circuit. Avoid material defect, material mix up, and welding defect.

 Do proper heat treatment Maintain tight inspection and quality control. Maintain optimum gas velocity Use quality fuel. Maintain excess air as recommended.

 Allow strain free expansion Insulation shall be carried out properly Proper storage of spare tubes and consumables. Engage qualified highly skilled welders. Maintain proper record for future reference.

TYPES OF WELDING
Butt Fillet Socket Build up Window

REQUIREMEMNTS
JOINT DETAILS BASE METAL DETAILS FILLER METAL SELECTION SHIELDING GAS POSITION OF THE JOINT PREHEAT PWHT

TECHNIQUE
STRINGER / WEAVE BEAD SMAW, SAW, TIG etc.

PREPARATORY WORKS

Welding machine Cutting set Gas cylinders Welding rod Tungsten rod Supply points 24V/230V/415V Safety accessories

MATERIALS USED
SA 210 Gr-C SA 106 Gr-B SA 209 T 1 SA 213 T 11 SA 213 T 22 SA 213 T 91 X 20 Cr Mo V 121

HEAT TREATEMENT

Preheating Inter pass temperature Post heating

PRE HEATING
Preheating is raising the temperature of the parent metal around the area to be welded to the specified temperature before welding and holding the temperature until completion of welding

PURPOSE OF PRE HEATING

Prevents risk of cracking in the weld and HAZ Reduces rate of cooling Reduces formation of residual stresses Reduces distortion due to welding

POST HEATING

Post heating is the heating the weld metal below the transformation range, holding for predetermined time and reducing the temperature at a controlled rate after completion of welding.

PURPOSES OF POST HEATING

Reduces HAZ hardness Relieves residual stresses Improves ductility Improves toughness Prevents premature cracks

STATUTORY
Central Boiler Board Controls Manufacturer Fabricator Erector Repairer Welder Testing agency Stress relieving agency

IBR Certificates
Form III - A for pipes III- B for tubes III C for fittings III D for pipes (Well known manufacturer) III E for tubes

STORAGE
Pipes & Tubes Both ends shall be plugged With identification marks ( Size & Material)
Electrodes To be procure from reputed firms with valid certificates To be stored in a dry room.

REPLACEMENT PROCEDURE
Intimation of failure Commencement report Obtaining permission Rectification ND testing Completion reports Hydraulic test Obtaining permission for light up

THANK YOU