Comm/ JB No 0993/C10

Rev 00 01/ 01.07.13

Isgec Heavy Engineering Ltd.

SECTION 10 – INSPECTION DURING MAINTENANCE

SAFETY FIRST

10.1 Safety Precautions Before canceling the PTW the recipient

Before carrying out inspection/ repairs on
any part of the boiler or its auxiliary
equipment and controls a work permit
authorizing such inspections/repairs
must be obtained from the relevant
authority. Supervisor should ensure that
the system is de energized / Isolated
before starting the job. On completion of
inspection/ repair the work permit must
be returned for cancellation. System is to
be normalized on cancellation of work
permits.
10.1 Permit to work (PTW) system
A permit to work is a printed form and
issued to employees before they may work
on specified items of plant. The objective
of this practice is to make it safe for
employee to work and the permit is the
guarantee of safety. Only authorized
persons of the owner are allowed to issue
the PTW after ensuring isolation/ safety
at the work place. Person incharge for
carrying out the work should be present
at job location with the PTW.
However the following must be made clear
time and again to the persons obtaining
permits.
For own safety they must ensure that
they do not work on equipment for
which a permit is necessary until it
has been issued.
If they are drawing permit themselves,
they should read carefully to make
sure that they know which part is
declared safe. If they have any doubt,
they must ask the engineer issuing
the permit.
All copies of a PTW must be signed,
PTW should be signed in the presence
of the engineer issuing or canceling it.
should sign the PTW with a statement
of work carried out.
NOTE:
Full proof mechanism must be
adopted in PTW system.
The issuing authority must ensure that
issue or cancellation of any permit in no
way affects safety of personnel or
equipment covered by a permit issued for
another section of plant.
During periodic overhaul it is a general
practice to isolate all electrical systems
and mechanism. While power testing of
any equipment, safety of personnel
working in adjacent areas is of prime
consideration. Warning must be given
and areas of doubt must be evacuated for
safety reasons.
NOTE:
Please refer O & M manuals of
OEMs for specific procedures and
operating and maintenance
recommendations for the various
auxiliaries.
General
When a boiler is shut down for
inspection/ repairs, it is either blow down
or filled completely with water depending
on the reason for the shut down. The
opportunity should be taken to inspect

1 X 80 TPH CFBC Boiler Section 10, Page 1

M/s. PT Tereos FKS, Indonesia

Isgec Heavy Engineering Ltd.
the boiler, both internally and externally,
as conditions permit.
In case boiler is to be emptied following
procedure shall be adopted:
When pressure in the boiler has fallen
to approximately 15 % of the working
pressure the blow downs may be
opened and the pressure reduced to
30 psig (2.1 kg /Cm2.g)
At this pressure the air release valve /
vents should opened. This will
prevent a vacuum forming within the
boiler as it cools further.
With all drain and vents open the
boiler is drained as far as possible.
If the boiler is to be kept out of service for
longer than 48 hours it must either be
absolutely dried out or completely filled
with water by adding chemicals.
Please refer Section 8 for Protection of
Idle Boiler
On completion of maintenance /
overhaul of boiler and its auxiliaries,
an inspection must be carried out to
confirm that job is complete and
correctly executed.
All surplus materials, tools etc. must
be removed from inside the furnace,
boiler drums, ducts, hoppers and
from the surroundings of boiler &
auxiliary plant.
Galleries and Ladders must be clear.
All drive couplings must be
disconnected to facilitate checking of
drive unit alignment and direction of
rotation.
Low voltage (24 volts DC supply)
electrical supply only should be used
for temporary inspection lamps and
extension leads.
Suitable protective Clothing, Gloves,
Face Masks, must be worn by
personnel entering boiler drums, duct
work, gas spaces etc.
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
A complete and adequate supply of
lubricants must be available at all
times. The grades recommended by
the various makers of the auxiliary
equipment in their literature must be
adhered to.
All threads must be treated with a
suitable lubricant on assembly to
facilitate disassembly and prevent
corrosion.
All screw threads/ valve spindles are
properly treated initially, and during
subsequent maintenance it is advised
that they are re-treated as a matter of
normal routine. For normal
applications Molybdenum Disulphide
grease can be utilized.
10.2 Boiler (Internals & Externals)
10.2.1 Boiler Drums
Certain baffle plates inside the drum
may also require, removal to give
access to the tube ends.
Cover the tube openings with
tarpaulin while cleaning the drums
Remove all debris and foreign matter
from drum.
Before entering a boiler drum
personnel must empty all loose items
i.e. mobile phones, Spectacles, coins,
cigarette lighters, penknives etc. from
their pockets. This will avoid the risk
of tubes becoming blocked by such
items falling into them causing
uneven water distribution,
overheating and subsequent tube
failure.
All tools and equipment taken into a
drum must be carefully catalogued to
ensure their removal before sealing
the drum. Anything that is
inadvertently dropped into a tube
must be reported immediately and it
should be removed. If a tube becomes
blocked permission must be obtained
from the inspecting authority for the
Section 10, Page 2

Isgec Heavy Engineering Ltd.
tube to be cut, the object removed and
the tube re-welded.
Remove any oil or grease traces using
a dry cloth.
Water Level indication:-
a. The water line is normally a well-
defined line, which indicates a
steady water level. An indistinct
broad bank will indicate an erratic
water level, the cause of which
must be sought in the boiler water
analysis.
b. Check the T.D.S. and alkalinity as
these may be such as to cause
priming or foaming.
c. Leakage from the feed pipe or too
vigorous a discharge from the riser
tubes may also cause this
symptom.
Check tightness of joints on all
internal pipes, and security of the
pipe clamps.
All joints of drum internals are fitted
with proper gaskets and there should
not be any gap between matching.
Before entering a boiler drum
personnel must empty all
loose items.
All items taken into a drum
must be carefully catalogued
and removed before sealing
the drum. Anything that is
inadvertently dropped into a
tube must be reported
immediately and removed.
Open blow down valves and wash
through drum with a high pressure
water jet. Care to be taken to prevent
blockage of blow down lines with
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
sludge. Use water only of the specified
feed water quality.
Check that all blind cap nuts are
tight.
WARNING :
Volatile solvents such as carbon
tetrachloride must not be used in
confined spaces, as their fumes are
highly dangerous.
Collect a sample of loose scale or
sludge for analysis.
Correct water treatment of both feed
and drum water will ensure the
internal cleanliness of both drums
and heating tubes between overhaul
periods.
NOTE:
Do not use oil or grease on nuts &
studs.
Cap nuts only are to be used
in drums to avoid thread
deterioration.
Examine the landing faces of drum
manholes/ man lids for blemishes
before shutting tight the man lids.
Manhole gaskets to be cleaned to good
Surface finish. Replace gasket if found
damaged.
Use only the specified gaskets. Before
installing the gaskets on drum
manhole, ensure the condition of the
gasket to withstand the pressure.
Section 10, Page 3

Isgec Heavy Engineering Ltd.
Ensure complete seal welding of hood
plate with steam drum
Gap is not allowed between baffle
plates two joints, cyclone separator
matching flanges, demister pads after
installation. Repair as required.
Ensure that the fixing of demister
pad, cyclone separator and other
Method of Expanding Tubes
internals are as per drawing.
Ensure saddle support of drums are
free from base saddle & bolts are in
hand tight condition in slotted holes
for free expansion & movement
10.2.2 Inspection Manifolds /
Header Stubs/ Tubes
Examine internal surfaces for rust,
loose deposits, grease. Any trace of
these must be manually removed.
High pressure water jet can be used
for this purpose.
Examine the landing on hand holes
and removable inspection caps for
blemishes that could affect the seal.
Replace and secure all inspection
caps.
Tube Repairs
Faulty expanded tubes are cut off
local to each end, the stubs remaining
are then trimmed and driven into the
drum or manifold from where they are
retrieved.
A new tube is prepared and expanded
in position in the manner described in
below.
AVOID DAMAGE TO TUBE
HOLES.
Welded Tubes
Faulty tube sections are simply cut
out and new sections welded in. The
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
relevant drawing must be consulted to
ascertain the correct weld preparation
and welding technique, material etc.
to be used. Ensure that a minimum
length of spool piece should not be
less than 200 mm and welded by
qualified welder.
Clean the new tube inside and out to
remove any protective coating, scale
or rust.
Remove any roll or die marks from the
tube ends. These must be smooth and
washed with a highly volatile grease
solvent to ensure that they are clean
and dry.
Clean the tube seats in the drum or
manifold in similar manner.
Select a tube expander to suit the
diameter and thickness of the tube
and the width of tube seat. The
length of the rollers should be
sufficient to expand the tube to a
diameter ½ or greater than the tube
diameter dependant on the gauge of
the tube.
Insert the tube in the seat and set the
inside projection to that specified on
the relevant drawing.
Insert the expander sufficiently far
into the tube to allow the small end of
the belling roller to enter. Then
withdraw the expander sufficiently to
ensure that a reasonable amount of
expansion takes place before belling
commences.
Turn the mandrill, the expander will
progress into the tube until the collar
abuts on the tube end. Expand the
tube slowly to avoid overheating. It is
preferable to under-roll rather than to
over-roll a tube since if a subsequent
hydraulic test shows up a leak it is to
be tightened by an additional roll. An
over-rolled tube however would have
to be removed and replaced by a new
tube.
Section 10, Page 4

Isgec Heavy Engineering Ltd.
Over rolling will be evidenced by
flaking of the tube metal under the
rollers.
Where straight rolling expanders are
used, the belling is done with a hand
belling tool.
Avoid excessive lubrication of
expander. Do not use mineral oils.
Recommended lubricant is undiluted
SHELL FRI 6 Soluble oil or equivalent
which is easily removed by the boiling
out process.
10.2.3 Furnace and Fuel feeding
When a markedly different draught
loss is observed compared with
previously recorded figures for similar
boiler conditions, this will indicate
that fouling has advanced to a stage
where external cleaning by wire
brushing is necessary.
Inspect the tube surfaces, air nozzles
opening, fuel spreaders opening and
refractory application work.
Observe any build up of deposits on
refractory surfaces, which are likely to
break loose as the boiler cools down.
Any debris should be removed before
re-starting the boiler, checking at the
same time for damage to refractory or
heating surfaces, which may have
been incurred.
Check the condition of fuel opening in
furnace and side sealing repair, if
necessary.
There should be no accumulation of
ash within the boiler.
Ensure seal around doors and
openings are as per drawing.
Ensure sealing rope or ceramic rope is
provided between all connecting
flanges in the fuel feeding system &
blots are full tightened.
Ensure internal surfaces of all
connecting duct, silo & chutes are free
from any debris, misalignment and
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
temporary supports to avoid jamming
of fuel during operation.
Ensure the tightness of foundation
bolts of gear box.
Ensure the lubrication of the drives as
specified in the lubrication schedule,
if required fill up fresh lubricants up
to the normal level
Check alignment of all rotary
equipments, foundation bolt tightness
& installation of proper safety guards.
Check alignment with drives (Fuel
feeding system drives) and ensure the
free rotation of the shaft. Megger value
& Earthing is to be ensured before
starting the motor. Take No load trial
of motor & record its running
parameters.
Ensure direction of rotation of the
drives as per drawing before coupling.
Ensure sealing of side water wall
panel with roof tubes
Ensure the attachment link of buck
stay is completely welded with water
wall & pins are tack welded at bottom
side & free for movement during
expansion.
Ensure sealing of pressure parts in
general.
Ensure supports in the integral piping
are as per drawing.
Ensure proper sealing of scallop plate
with tubes and seal boxes.
Ensure proper sealing of air nozzles
with the fins.
Ensure saddle support of all headers
are free from base saddle & bolts
looseness is adjusted as per drawing
for free expansion & movement.
10.2.3.1 Refractory Inspection
Every opportunity should be taken to
inspect the brick work/ refractory
inside the boiler for general condition,
erosion and formation of cracks.
Section 10, Page 5

Isgec Heavy Engineering Ltd.
The refractory must be stored in a
clean, dry place where it is not likely
to be disturbed and contaminated by
water/ oils or grease which will
destroy their bonding properties.
Any damage incurred or discovered
must be repaired by dismantling the
panel to the root and recasting.
Adhere strictly to the maker’s
instruction for mixing and applying
the refractory material.
Drying out after repair must be done
according to the refractory dryout
procedure.
10.2.4 Super heater
Ensure the gap between super heater
coil bend to adjacent pressure part
panel is as per drawing
Ensure the gap between super heater
coil to side water wall panel is as per
drawing.
Ensure that guide plates are fitted in
the lugs provided on super heater
coils are as per drawing. Ensure that
there is a sufficient gap between the
guide plate and side panels so that
they do not rub after expansion.
Ensure the alignment & pitch of super
heater coils are as per drawing.
Ensure super heater coils sealing with
panel tubes & welding of seal boxes
are as per drawing
10.2.5 Economizer
Ensure the gap between economizer
coil to side casing is as per drawing
Ensure that Soot blower support
plates orientation & elevation are as
per drawing.
Ensure that inner casing plates are
erected and welded as per drawing.
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
Ensure the alignment & pitch of
economizer coils are as per drawing.
Ensure economizer coils sealing with
casing are as per drawing.
Ensure the gap between Soot blower’s
Lance pipe to coils and outer casing is
as per drawing.
Ensure expansion joints are as per
drawings and expansion clearances
are adequate.
10.2.6 Deaerator
Ensure sliding support between the
base and one end saddle support of
deaerator are as per drawing.
Use wire brush to clean deaerator
surface and remove any dirt, rust or
mill scale, also clean the surface of
the deaerator manhole area.
Inspect the deaerator storage tank,
scrubber system and deaerator head
before filling the deaerator.
Ensure cleanliness of holes in inner
jacket of scrubber system inside the
storage tank.
Ensure integrity of welding of spray
nozzle box, SS Tray & other internals
in deaerator head & spray head.
Check for proper gaskets in branch
pipes.
Examine the landing faces of
deaerator manholes/ man lids for
dent / marking before shutting tight
the man lids.
Check the pipe line supports as per
drawing and pre set at cold load
condition.
Check that all the Nuts of U clamps
are tight and tack welded so that they
do not fall down during operation due
to vibrations.
10.2.7 Ducting, Bunker, Hopper &
Section 10, Page 6
 Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
Isgec Heavy Engineering Ltd.

Expansion joints A. Gas tightness test.

Ensure sealing rope or ceramic rope is
Start the ID fan and PA fan. Slowly
provided between all connecting
regulate the VFD in the circuit to raise
flange, manhole & bolts are fully
the pressure of the furnace to about
tightened.
100 mmwc.
Ensure engagement or alignment of
Take a burning swab/ soap solution
support hangers and supporting rods
and put it around
are as per drawing and supports are
pre set for the cold load condition. i. Manhole & Peephole doors
ii. Duct Joints
Ensure sealing of air / gas through
iii. Fan flanges
damper’s spindle bearings and
iv. Hopper Joints
tightness of shutoff dampers.
v. Expansion bellow Joints
Clean expansion joints to allow proper vi. All flanged Joints
flexibility and sealing of flue gas / air.
Flame will deflect wherever leakage
Ensure baffle plates welding, its will be there. Soap solution shall show
supports and their distance between bubbles.
baffle plates are as per drawing.
Mark the leaking point and carry out
Ensure that quadrants or indicators rectification.
are showing correct reading for SHUT
and OPEN damper positions and Repeat the test until all leakages are
marked on the duct for clear arrested.
indication.
B. Air Tightness Test
10.2.7.1 Gas and Air Tightness Test
Start the ID fan and PA fan. Slowly
It is generally noticed that at times regulate the VFD in the circuit to raise
during operation of boilers the the pressure of the fans to maximum
leakages in the air and gas side of the operating pressure of the fans.
boiler are high which causes loading All dampers in the air circuit near the
of fans. Such undesired loading acts furnace entry shall be closed.
as a restraint for loading the boiler or
in fixing the correct regime of Take a burning Swab/ Soap solution
combustion. and put it around joints in the
ducting. Flame will deflect wherever
The best way of eliminating this is to leakage will be there. Soap solution
carry out Air and Gas tightness test shall show bubbles.
on the vulnerable points in boilers.
Mark the leaking point and carry out
Leakage test of individual ducting / rectification.
hoppers to be carried out by running
respective fans. Repeat the test until all leakages are
arrested.
Vital areas that require specific attention
during checking :

i) Tubular Air heaters

ii) Duct joints
10.2.7.2 Procedure iii) Welding joints
iv) Damper and expansion joints

1 X 80 TPH CFBC Boiler Section 10, Page 7

M/s. PT Tereos FKS, Indonesia

Isgec Heavy Engineering Ltd.
Other Alternate procedures for
checking:
Smoke Test: This test is similar to air
and gas leak test with an addition of
smoke generation in the boiler before
pressurizing. Any leakages shall be
identified visually by smoke coming out
from leaking areas. Smoke can be
generated by smoke bombs, smoke
generating machines or by firing wood/
jute/ cotton waste etc.
Kerosene Test: This test is conducted for
detecting the leakages thru the weld
joints normally in ducts. A paste of lime/
chalk is applied on one side of the joint
and after drying, Kerosene is sprayed on
the other side of the joints. The leakage
areas shall be seen as wet areas on the
side where lime/ chalk is applied.
WARNING :
Smoke generating machines using
petroleum fuels must not be used
as there is a fire/ explosion hazard.
Machines using organic chemicals
like Glycerin & Rose water can be
safely used.
Care must be taken while handling
Kerosene for the fire hazards
10.2.8 Boiler house piping & valves
Lubricate the valve spindles and
adjust gland packing as necessary for
free movement.
Each valve must be checked for full
and free movement of the spindle
between SHUT and OPEN limits.
Position indicators must be checked
for correct indication both at local and
remote.
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
Care must always be exercised not to
over tighten valves when shutting.
10.2.9 Fans
Clean fan casing, impeller and
connecting ducting and remove all
obstruction.
Ensure tightness of all mountings and
foundation bolts.
Ensure bearing is free from dust &
other foreign material & recommended
lubricant is filled.
Check the end gaps on both sides of
floating bearing and ensure that it is
as per drawing. Ensure that lock rings
are installed in the fixed bearing.
Ensure locking arrangement of
bearing sleeve with lock nut and
locking arrangement of hub with shaft
is as per drawing.
Ensure fan bearings (DE & NDE)
make a full contact at bottom surface
& all around with bearing housing.
Ensure the fixing of fan shaft seals at
fan casing are as per drawing.
Check the clearance between rollers /
balls and the inside diameter of the
bearing outer ring (cage).
Check the distance between the shaft
ends (DBSE) and gap between both
halves of the coupling is as per
drawing.
Check alignment with drive and
ensure the free rotation of the
impeller.
After erection, Megger value &
Earthing is to be ensured before
starting the motor. Take No load trial
of motor & record its running
parameters.
Ensure direction of rotation of the
drive is as per drawing before
coupling.
Check coupling is properly fitted &
alignment is perfectly done.
Section 10, Page 8

Isgec Heavy Engineering Ltd.
Check the operation of dampers and
ensure that all the flaps are in
operating condition. Ensure that
OPEN & CLOSE direction is clearly
marked.
Start the fan with minimum speed.
Open the dampers.
Check vibration, temperature, motor
current, abnormal sound etc.
Increase speed of the fan up to full
speed, keeping a continuous watch
on bearing / casing temperatures,
vibration, motor current etc. Shut
down immediately if any abnormality
is observed. Warning of approaching
seizure will be given by an increase of
load (Amps) on electric motors.
Record all temperature, vibration and
current readings of this initial run-up
period at 10 minutes interval.
10.2.10 Pumps
Check cleanliness of suction strainer
before installation.
Rotate the shaft by 180 degree of a
multistage pump every week to avoid
rusting, sagging & corrosion during
non working condition (Idle). Shaft
should be hand free.
Ensure the flushing of cooling water
supply line to the pump and check its
pressure.
Check the alignment reading of the
coupling of pump by three dial gauge
is within 0.04 mm/m in axial &
transverse directions. The alignment
is to be checked both with and
without connection of piping.
Check that there is no leakage from
the mechanical seal. In case gland
seal is fitted, drop by drop leakage
shall be ensured to allow cooling of
gland.
Check the distance between the shaft
ends (DBSE) and gap between both
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
halves of the coupling is as per
drawing.
Megger value & Earthing is to be
ensured before starting the motor.
Take No load trial of motor & record
its running parameters.
Ensure direction of rotation of the
drive is as per drawing before
coupling.
Ensure cooling water fittings for
glands & instrument fittings in the
pump are leak free and orientation is
as per drawing.
If bearings are water-cooled check
water supply and its pressure. If
glands are water-cooled and water
sealed, ensure that water being used
conforms to OEM recommendation.
Check bearings are lubricated as per
lubrication schedule.
Open suction valves & check for
sufficient suction pressure & suction
differential pressure across strainer.
Ensure that minimum recirculation,
balancing leak off line valves & cooling
water supply for pump are locked
open.
Ensure all instrument, interlock &
protection are in line & working
satisfactory.
Start pump and keep a constant
watch on suction pressure, suction
DP, balancing leak pressure discharge
pressure, bearing temperature,
vibration, motor current, abnormal
sound etc. Shut down immediately if
any abnormality is found.
Record the temperature, vibration,
current, suction pressure, balancing
leak off pressure etc readings of this
initial run-up period at 10 minutes
interval.
Section 10, Page 9

Isgec Heavy Engineering Ltd.
For Centrifugal Pumps
These Pumps must only be
started with suction valve
open and discharge valve in
SHUT condition. As pump
picks up speed discharge
valve is to be opened
immediately.
For Positive Displacement
Pumps:
These pumps must only be
started with both the suction
and discharge valve OPEN to
avoid overloading and damage
of pump.
10.2.11 Boiler Valves and Fittings
Lapping Equipment
Lubricate the spindles and adjust
gland packing for free movement.
Each valve must be checked for full
and free movement of the spindle
between SHUT and OPEN limits.
Position indicators must be checked
for correct indication at local and
remote.
Care must always be exercised not to
over tighten valves when shutting.
Normally the valves are of such design
as to allow repeated reconditioning of
seats by facing or lapping depending
on the seat condition. Do not attempt
to lap out deep blemishes. Time can
be saved by refacing, followed by a
final lap.
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
When shutting a cold valve,
allowance must be made for
spindle expansion in warm up
condition, by easing back a
little from tight shut position.
Failure to take this
precaution shall result in
spindle distortion and valve
failure.
Valves and seats must be lapped
independently using suitable lapping
plates. These should be kept perfectly
flat and should be renewed upon if
any signs of wear becoming apparent.
Lapping abrasives should be used; the
natural porosity of the lapping plates
will retain all that is necessary to
produce a finished surface.
Two large grinding plates are provided
for lapping the various discs for valves
of all sizes. These plates are used also
for reconditioning the plates used for
lapping the valves seats. When
reconditioning the lapping plates it is
necessary to remove the pilot piece in
order that the plate can be laid flat on
the grinding plate. The pilot piece is
replaced after reconditioning.
Safety valve heads cannot be lapped
on the flat grinding plate; a set of
special plates for this purpose is
required.
A complete set of lapping plates to
suit all sizes of valve seats is to be
maintained by the maintenance team.
Section 10, Page 10

Isgec Heavy Engineering Ltd.
10.2.12 Water Level Gauges
The water level gauge must be
properly cleaned for easy visibility and
proper illumination to be provided.
Wherever a remote reading gauge is
provided, this must be crosschecked
with local gauge for accuracy at
regular intervals.
10.2.13 Instruments and Control
Equipment
Correct installation and functioning of
instrumentation is essential for the
operation of the boiler. Therefore
availability of all instruments and
controls must be ensured before
lighting up.
Ensure that calibration of all draught,
pressure gauges and transmitters
(pressure / temperature / level / flow
/ Position) is completed
Check all control equipment ensuring
that actuators respond in correct
sense. Lubricate according to makers
recommendations.
Check limits switches of all actuators
for proper functioning.
Ensure all VFD & Control panels are
tested and calibrated
Ensure power cylinders are operating
satisfactorily.
Ensure that control system, UPS is
working satisfactorily.
Ensure all control logics are checked
for proper functioning.
Interlocks
Interlocks are provided to safeguard
the boiler and its associated
equipment from possible damage due
to component failure or some
abnormal occurrence in boiler
operation.
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
WARNING :
Boiler and auxiliaries interlocks
must never be bypassed. Any bypass
for simulation if required shall be
done only when the boiler is in
stopped condition. Any such event
must be properly recorded with
reasons of doing so and must be
normalized without fail before
restart.
By simulating the various failure
conditions and observing the
sequence of action induced, interlocks
can be checked for correct setting and
functioning.
Ensure that all protection & interlocks
are checked for proper functioning.
10.2.14 Air Pre heater (APH)
Ensure sealing of air heater bottom
tube sheet with the supporting
structure to avoid any leakage during
operation.
Ensure complete sealing of air heater
tube sheets with expansion bellow/
casing to avoid any leakage during
operation.
Ensure baffle plates welding and its
supports and distance between baffle
plates are as per drawing.
Ensure sealing rope or ceramic rope is
provided between all connecting
flanges, manholes and bolts are fully
tightened.
10.2.15 Soot Blowers
Ensure the inclination of lance in cold
condition is as per drawing so that,
during operation soot blower will be
perpendicular to the wall in the
horizontal plane.
Section 10, Page 11
 Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
Isgec Heavy Engineering Ltd.

Ensure that the nozzle orientation of Check bolt tightness and tack welding
lance is parallel to the coils to be of tumbling hammers so that they do
cleaned in home position. In rotary not get dislodged during operation.
and short retractable blowers, the
Check alignment with drive and
nozzles position must be aligned with
ensure the free rotation of the rapping
centre line between the two adjacent
shaft.
coils.
Ensure bearings and gear boxes are
Ensure the gap between lance edge
lubricated as per lubrication schedule
and the adjacent water wall tube /
casing is as per drawing. Ensure earth resistance is below one
ohm (1 ohm). Check that independent
Check the condition of sleeves and
earthing has been provided for
rectify as required.
individual TR sets, ESP MCC panels
Ensure that rotary soot blower lance and Rapping panels.
is not under tension due to
Check that mechanical door interlock
intermediate supports.
(Castle Keys) are installed and
Ensure that gland packing of specified sequence is checked before charging
quality is filled in the stuffing box of the ESP.
feed tube and valve stem (poppet
valve)
Ensure proper lubrication of moving 10.3 Long Term Maintenance
parts of the soot blower. Schedule
Ensure proper operation of poppet
valve w.r.t. the limit switches.
Ensure direction of rotation of the
drive is as per drawing before WARNING :
coupling.
Ensure that the poppet valve is set as Do not attempt repair
per the operating pressure. beyond your capabilities.

10.2.16 ESP
1. Steam Drum
Ensure alignment of discharge
electrodes with respect to collecting Operational Checks:
plates to maintain corona gap i.e. T-
gauge passing Check for steam and water leaks from
connections and fittings to the drum.
Ensure that all opening in hopper are
sealed and hopper welding is Prior to Shutdown:
completed in all respect to make it air
Check drums pressure gauges, safety
tight.
valves water level gauges for accuracy &
Ensure that any cutouts made in reliability.
hopper/ ESP for installing the
instruments are properly sealed. Annually:
Special care is to be taken in double
casing areas (for hopper heaters) Inspect the drum internally for evidence
where sealing is to be done in both of the following:-
inside and outside plate. Surface cracks or grooving

1 X 80 TPH CFBC Boiler Section 10, Page 12

M/s. PT Tereos FKS, Indonesia

Isgec Heavy Engineering Ltd.
Carryover
Any sign of oil or other substances
that may have entered the boiler.
Signs of pitting
Sludge or scale accumulation
Corrosion
Clean out any debris that has
accumulated inside the drum. Remove
any scale and sediment.
Inspect for a noticeable and smooth
water level.
Inspect for welding condition of hood
plate to drum
Inspect the drum shell between tube
openings (ligaments) for pitting or
cracking.
Check for and clean any scale or sludge
in the following areas:-
Primary scrubber elements.
Feed water line.
Continuous blow-down line.
Chemical feed line.
Openings to safety valves must be free
of obstructions, such as mud or scale
Repair the following if any trace of leaks
or obstruction has been found during
operation:-
Connections to blow-down
Connections to water columns and
level gauges.
Connections to pressure gauges
Connections to transmitters
Inspect the drum internals to ensure that
joints in the following areas are tight:-
Steam cyclone separators.
All baffles.
Steam scrubbers.
Chemical, feed and blow-down lines.
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
Mark all adjusted internals for future
removal and reinstallation.
Inspect and replace manhole gaskets
if damaged or deteriorated.
Remove all drum internals and
inspect for wear, corrosion & erosion.
2 Headers (Manifolds / Header
Inspection Stubs)
Annually:-
Examine internal surfaces for rust,
loose deposits, grease. Any trace of
these must be manually removed.
High pressure water jet can be used
for this purpose. Water used must be
of same quality as that of feed water.
Examine the landing on hand holes
and removable inspection caps for
blemishes that could affect the seal.
Inspect header caps / flange joints for
signs of leaks or cracking by DP test.
Every Five Years:-
Check headers for the Corrosion.
Inspect for cracking of welds in the
areas listed below using non-
destructive testing method:-
a. Tube to header welds.
b. Header shell between tubes
(ligaments).
c. Nozzle to header welds.
d. Lug and hanger connections.
e. Thermo-wells & hand-hole fittings.
f. Longitudinal and circumferential
welds.
g. Drain connections.
h. Cracking in safety valve opening.
Section 10, Page 13

Isgec Heavy Engineering Ltd.
3 Furnace
Operational Checks:-
If possible, inspect the slagging
condition of furnace walls through
ports. Use extreme caution when
doing so. Always wear tinted goggles
or shield to protect eyes from harmful
light rays, slag or ash particles. Do
not stand directly in front of open
ports.
Walk around the exterior and observe
for any hot spots or gas leaks.
Prior to Shutdown:
Check for gas leaks at observation ports,
as well as manhole and access doors.
Note or mark any areas in which leakage
is occurring (for ease of location during
shutdown).
Annually:-
Inspect the tube surfaces for signs of
leaking, corrosion, overheating
(blistering and bulging), warping,
misalignment, pitting, or cracking.
Inspect furnace side wall at junction
of furnace and convection pass for
cracking due to differential expansion.
Inspect furnace sealing for
leakages.
Check the condition of all refractory.
Clean and reset manholes. Inspect
condition of gasket.
Inspect the condition of seal around
doors and openings.
Inspect the inner surfaces of furnace
wall tubes for deposits and scale.
Inspect the condition of fuel feeding
system
Every 5 years:-
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
Take random ultrasonic tube thickness
measurements in critical locations, such
as:-
At furnace headers & tubes.
Around fuel inlet opening.
4 Super heater
Annually:-
Externally inspect tubes for signs of:-
- Overheating (swelling or blistering)
- Warping
- Misalignment
- Corrosion
- Fouling
- Erosion
If internal deposits are suspected,
tube section should be removed for
inspection, the determined and
corrected prior to returning to service.
Inspect supports.
Check attachment to tube welds for
cracking or wear.
Check supports, spacers and seal
plates for proper location and
condition, attachment to tube welds.
any Inspect the condition of super heater
seals where the tubes penetrate the
wall panels.
Inspect the condition of sleeves
wherever provided.
5 Economizer
Operational Checks:-
Listen for any unusual noise around
the economizer section, which may be
indicative of an economizer leak (i.e.
hissing)
Section 10, Page 14

Isgec Heavy Engineering Ltd.
Inspect ash hoppers to make sure
they are emptied properly.
Prior to Annual Shutdown:-
Annually:-
Visually inspect economizer to locate
any deposits that may interfere with
heat transfer or block gas paths.
After visual inspection, determine if
cleaning is necessary. Perform a water
wash directly after shutdown using a
warm alkaline solution with a pH level
between 10.5 and 11.0 if required.
Care must be taken to dry the
surfaces out be operating the fans.
Externally inspect tubes for signs of:
- Overheating (swelling or blistering)
- Warping
- Misalignment
- Corrosion & Erosion
- Fouling
If pitting has been found in the steam
drum take economizer tube sample
and inspect them internally for
pitting.
If internal deposits are suspected,
tube sections should be removed for
inspection, the cause determined and
corrected prior to returning to service.
Check & Inspect attachment to tube
welds for cracking or wear.
Inspect economizer hopper trusses
and gusset plates for erosion and
corrosion damage.
Check supports, spacers and seal
plates for proper location and
condition, attachment to tube welds.
Inspect expansion joints for signs of
cracking or tears.
Inspect the condition of seals where
the tubes penetrate the casing.
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
Inspect the condition of sleeves
wherever provided.
6 Hopper
Operational Checks:-
Inspect for air leaks or gas leak around
the hopper.
Inspect for signs of overheating
Review the pressure drop between the
hopper and furnace regularly.
Changes in this pressure for a given
load condition may indicate for
restriction problems.
Annually:-
Inspect hopper for accumulation of
ash & other foreign materials.
Inspect all internal baffles, tie-bars
and trusses to ensure they are in good
condition.
Check to ensure that the dampers are
clean and free to move. Lubricate all
moving parts with a high temperature
anti-seize compound.
Inspect hopper corners and expansion
joints for signs of cracking or tears.
7 Ducts and Dampers
Operational Checks:-
Check around all ducts and flues for
signs of leakage.
Check position of fan dampers.
Inspect ducts and expansion joints for
signs of cracking or tears.
Annually:-
Checks for Flue Gas Path
Gas tightness.
Section 10, Page 15

Isgec Heavy Engineering Ltd.
Disengagement or misalignment of
support hangers and supporting rods.
Tightness of the mounting hardware.
Corrosion and erosion on inner
surfaces.
Excessive deposits of dust and ash.
Inspect all refractory surfaces exposed
to flue gases.
Checks for Duct
Air tightness.
Disengagement or misalignment of
support hanger and supporting rods.
Tears and cracks at corners.
Checks for Air/ Flue gas Dampers
Leakage through damper spindle
bearings and shaft packing glands.
Sticking operation of control dampers
over the control range.
Warp age & Overheating.
Tightness of shutoff dampers & broken spring. Measure and record
Ensure vanes are free to operate.
Lubricate all drives & bearings.
Examine damper assemblies for wear
of blades and blade spindles.
8 Expansion Joints
Inspect the internal and external
condition of all expansion joints
(especially non-metallic types).
Determine if any unusual wear or
pluggage has occurred.
Inspect for warp age or cracks.
Clean expansion joints and remove
excessive dust collection to allow
proper flexibility and sealing of flue
gas.
9 Supports
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
Prior to Annual Shutdown:-
Inspect external areas of boiler for
damaged support equipment. By taking a
walk around piping systems, and
indication of support and supported
equipment, condition can be obtained.
This will aid in the formation of a
shutdown maintenance schedule.
Annually:-
Inspect boiler for alignment, noting
any abnormal movement
Check condition of header guides and
supports to ensure alignment yet
permit expansion of tubes without
excessive strain.
Check that main steam piping and
connected equipment are properly
aligned and have proper clearance for
expansion.
Inspect for sings of support failure
such as changes in scale readings on
flexible type supports.
On spring type hangers, check for
spring lengths.
Check piping supports and hangers
for disengagement or misalignment.
Verify each hanger is carrying load.
Inspect hanger rods for tightness.
Check for corrosion of hanger
components, including tube spacers
and support saddles. If corrosion is
found, apply a rust inhibitor.
Look for broken or cracked hanger
rods, pins, lugs, ties or saddles.
Tighten any loose nuts.
For constant support hangers, inspect
levers and remove any dust deposits
found. Re-pack with greases.
Inspect drum and down-comer
hydraulic shock arrestors for damage.
Check the fluid lever and look for fluid
leakage.
Section 10, Page 16

Isgec Heavy Engineering Ltd.
Every 2 Years:-
Inspect buck-stays for straightness and
their attachment to furnace walls.
Every 5 Years:-
Perform visual and magnetic particle
inspection of support ties, saddles and
attachment weld.
10 Refractory and Insulation
Operational Checks:-
Inspect around all air and gas
passages for possible air or gas leaks.
Inspect around the boiler casing for
gas leaks or hot spots.
Annually:-
Inspect the condition of the refractory
around fuel feeder opening / throats
and surrounding wall area. Repair or
replace as necessary.
Inspect the condition of refractory.
Repair wherever necessary.
Inspect the condition of the refractory
around access doors and observation
ports.
Inspect the refractory seal in all seal
boxes.
Inspect the condition or refractory
surface exposed to flue gases like as
Furnace zone, Chimney, ash hoppers,
scrubbing system etc.
11 Safety Valves
Operation Checks:-
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
Check for leakage at valves by audio-
visual inspection, at normal operating
pressure.
Check the clearance of the lifting lever
on the leaking valve. Note and log the
severity of any leaky safety valve.
Check drain lines and drip pans are
not plugged.
When safety valves do operate, note
the opening and resetting pressures
as accurately as possible. After
normal operating pressure has
resumed, check for leakage at valve.
Incorrect setting will require
adjustment.
Assess leakage rate from weekly
checklist if a noticeable increase has
occurred. Plan for an early shutdown
to repair. Early shutdowns can reduce
damage to valves.
Annually:-
Clean internal parts, there should be no
accumulation of rust, scale or other
foreign substances, which will interfere
with their free operation. Recondition
valve seats (laps) (if required).
Refer Manufacturer O & M Manual for
Detail Overhaul
12 Boiler Valves
Operational Checks:-
Make note of any leaky valves and
prepare a report for type & class of valve,
location, quantity and stock in hand.
Annually:-
Check seating surfaces of body and
disc for flaws or cracks. Re-lap if
repairable.
Section 10, Page 17
 Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
Isgec Heavy Engineering Ltd.

Examine the back seat for erosion and service and replace, install new glass
corrosion. Replace if erosion is too if it is discolored, chipped. If for any
deep. reason the glass and cushion gaskets
are removed, replace them.
Inspect the gasket between body and
bonnet for dents, friction flaws,
erosion and corrosion. Repair gasket Every 6 months:-
seat by sand paper or lapping. If a
flaw still exists in the redial direction, Replace mica gasket and glass
discard and replace. assembly.
Check the stem for cracks, bend, Perform a total rebuild as a
flaws deflection, deformation and preventative measure, since ports
erosion of packing contact section. If tend to fail in succession. Follow
cracked, replace. Minor defects can be proper torque tightening procedure.
repaired by sand papering.
Check the stuffing box for erosion and
Annually:-
corrosion. Repair by lapping if flaw is
not too deep.
Check that all connecting piping to
Check, guide sections of body and the column and glass is clear and
disc for erosion and corrosion. unobstructed.
Check bonnet bolts, hinge bolts and Repair any leaks of steam or water
nuts for erosion, corrosion and coming from piping or valves observed
elongation of screw pitch. Replace if during operation.
deformed.
Refer Manufacturer O & M Manual for
Replace gasket and gland packing. Detail Overhaul

13 Water Level Indicators

14 Long Retractable Soot Blowers:
Operational Checks:-
Operational Checks:-
Check to see if the gauge or indicator
is showing the proper water level. On While doing a routine inspection of the
water gauges this can be done by boiler, inspect for steam traps and
opening the drain slightly, then condensate, steam or oil leaks from the
quickly closing the drain to avoid soot blowers.
damage to the mica gaskets. Watch
for the water level to return to its
normal position. Weekly:-
Replace any burnt out indicator During routine soot blowing, check and
lights. verify blowing pressures at individual soot
blowers
Check for water or steam leaks from
ports or from the connections to the
drum. Leakage at the water column or Monthly:-
drain connection will cause a false
water level in the gauge glass. Perform a visual inspection of soot
Inspect glass for discoloration or blower at rest and during normal
fouling. If glass appears dirty (fouled), operation to check for proper
blow down to clean it, remove it from extension and retraction.

1 X 80 TPH CFBC Boiler Section 10, Page 18

M/s. PT Tereos FKS, Indonesia

Isgec Heavy Engineering Ltd.
Check for proper direction of rotation.
Check the extended or blowing
position of the nozzle or element to
ensure that it will give good cleaning
results without damaging the walls &
lance, which it is, designed to clean.
Check the start and finish-blowing
arcs on corner mounted blowers and
those, which are mounted adjacent to
division walls etc., to ensure that the
blowing medium is being directed in
the proper area for best cleaning
results and to avoid damaging tubes.
Check the wall-box sleeve alignment
to boiler wall to ensure it is
perpendicular (plumb) with the
vertical place of the wall in all
directions.
Check for condensate or slag in wall-
boxes. Condensate in a wall-box can
indicate a leaky puppet valve, while
slag can reveal the need for seal air.
Ensure that the wall-box seal plate is
free to float.
Inspect wall-box and sleeve for
damage. A damaged wall-box and
sleeve can result in deteriorated wall-
box and damaged boiler wall
refractory or insulation. This in turn
can result in support problems and
casing leaks.
Ensure the proper operation of all
moving and mechanical part.
Check the condition of the expand
cable.
Inspect tubes and tube sleeves in the
vicinity of soot blower paths for
possible metal loss due to erosion,
steam cutting, rubbing of soot-blowers
or corrosion.
Check condition of the feed tube and
valve stem packing. Replace if hard
and dry. Add more packing rings to
the feed tube gland as necessary. Do
not over tighten.
Check puppet valve condition. If the
valve shows signs of leakage, re-lap it
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
and inspect internals for corrosion or
damage.
Ensure the valve spring, spring
retainer, yoke and trigger are intact,
and that the lance tube is not riding
on the wall box seal.
Check for Lubrication of rotating
parts.
Test forward and reverse limit switch
actuator for proper spring action and
check for broken or distorted parts.
Check auxiliary lance and feed tube
support for the brackets, roller, fork
lever etc.
Refer Manufacturer O & M Manual for
Detail Overhaul
15 Rotary Soot Blowers:
Operational Checks:-
While doing a routine inspection of the
boiler, inspect for steam traps and
condensate, steam or oil leaks from the
soot blowers.
Weekly:-
During routine soot blowing, check and
verify blowing pressures at individual soot
blowers.
Monthly:-
Perform a visual inspection of blowers
at rest and during normal operation,
to ensure proper rotation and re-set.
Check for proper direction of rotation.
Check the extended or blowing
position of the nozzle or element to
ensure that it will give good cleaning
results without damaging the walls &
lance, which it is, designed to clean.
Check the start and finish blowing
arcs of blowers to ensure that blowing
medium is being directed in the
proper area for best cleaning results
and to avoid damaging tubes.
Section 10, Page 19

Isgec Heavy Engineering Ltd.
Check the wall-box sleeve alignment
to boiler wall to ensure it is
perpendicular (plumb) with the
vertical plane of the wall in all
directions. Ensure that the wall-box
seal plate is free to float.
Check for condensate or slag in wall-
boxes. Condensate in a wall-box can
indicate a leaky puppet valve, while
slag can reveal the need for seal air.
Ensure that the wall-box seal plate is
free to float.
Inspect wall-box and sleeve for
damage. A damaged wall-box sleeve
can result in deteriorated wall boxes
and damaged boiler wall refractory or
insulation. This in turn can result in
support problems and casing leaks.
Ensure the proper operation of all
moving and mechanical parts.
Inspect for main bearing condition
and drive pins if worn-out replaced
the same.
Inspect tubes and tube sleeves in the
vicinity of soot blower paths for
possible metal loss due to erosion,
steam cutting, rubbing of soot blowers
or corrosion.
Check puppet valve condition. If the
valve shows signs of leakage, re-lap it
and inspect internals for corrosion or
damage.
Ensure the valve spring, spring
retainer, yoke and trigger are intact,
and that the portion or the trigger the
makes contact with the valve stem
does not show excessive wear.
Check for Lubrication of rotating
parts.
Refer Manufacturer O & M Manual for
Detail Overhaul
16 Fans
Operational Checks:-
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
Inspect bearing lubrication and check
for proper oil level / grease. Lubricate
drive assembly linkages
If ring-oiled, check for free revolution
and adequately distributed oil.
Check for loose material, which may
get sucked into the fan.
Check bearing temperatures. If hot,
determine cause and remedy the
situation.
Ensure a flow of water is getting to the
bearings and water outlet temperature
is not excessively warm (if water
cooling is provided)
Ensure that fan shaft seals and
bearing seal are intact and functional.
Feel the unusual motor or fan noises,
check vibration and take vibration
readings.
Maintain control room records / log
book for bearing temperature,
vibration, oil usage, damper operation
and indication etc. on Daily / shift
basis.
Annually:-
Check motor & fan bearing condition
and change bearing oil / grease.
Analyze a sample from each bearing.
Flush cooling water jackets it
provided.
Check motor-fan alignment and its
coupling
Inspect Fan shaft seals, Fan casing,
cone and ducts, Impeller for wear and
corrosion.
Check foundation for cracking,
sagging or any other deterioration to
concrete or steel works.
Lubricate the linkage connections of
dampers.
Check the static and dynamic
balancing of the fan.
Section 10, Page 20

Isgec Heavy Engineering Ltd.
Check the fan shaft for any cracks by
D.P. Test, Ultrasonic testing etc.
Fan Housing
Check for signs of wear or corrosion,
damage.
Check tightness of foundation bolts.
Visually inspect for cracks
Impeller
Check for abrasive wears on blades,
casing, and cone.
Check that the impeller is completely
clean, and that the blades and the
shroud are free of any build up.
Check that the impeller is tight on the
shaft.
Check that the shaft is straight and
crack free.
Check for mechanical damage
indicating an object has entered the
impeller during operation.
Visually inspect for weld cracks, if in
doubt, perform a liquid dye penetrate
test.
Inlet Cone
Check for signs of wear or corrosion,
damage.
Check clearance and fit up, ensure it
is correct.
Bearings / Plummer Block
Clean all bearings and Plummer
blocks. Check clearance between
rollers / balls and the inside diameter
of the bearing outer ring. Check
bearing gaps in housing.
Inspect the bearing seals. Take drain
oil, grease sample.
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
Inspect rollers / balls for flat spots,
pitting and irregular surface & Check
bearing hold-down bolts for tightness.
Apply new sealant, reassemble and re-
torque bolts.
Inspect bearing sleeve and lock nut
with washer for wear, tear and
looseness.
Inspect oil seals, if found damaged
then replace.
Check all instrumentation operations.
Lube Oil Sets
Take oil samples from all units.
Clean unit, replace oil and filters.
Check pressure and flow settings.
Checks all hoses and pipes for leaks.
Check instrumentation and standby
pump operation.
Coupling
Clean and inspect for internal wear.
Renew all worn sealing devices.
Renew all lubricants.
Re-torque all bolts.
Check for proper gap setting.
Check alignment and realign if
required.
17 Drag chain feeders
During every shut down of the boiler,
drag chain feeders chain to be checked for
looseness and to be tightened. Worn out
plates, chain links to be replaced.
Alignment of the motor with the gear
boxes to be checked. Drive side chain to
be cleaned and lubricated with fresh
grease. Non drive end side sprocket self
cleaning plate bolts to be tightened.
Inspection of inner side liner to be done. If
any abnormality found, it is to be
rectified. All the bearings to be cleaned
Section 10, Page 21

Isgec Heavy Engineering Ltd.
thoroughly, grease should be completely
removed and filled with fresh grease.
18 CFBC Systems
Wall seal Blowers
Wall seal blowers belt tightness should be
checked during regular operation of the
unit as well as during shut down time. If
any of the belts found worn out, all the
belts should be replaced simultaneously.
Alignment of belt should be checked and
proper tightness of the belt to be
maintained.
Suction filter cleaning to be carried out
periodically and during each shutdown.
Tightening of the foundation bolts and
bolts of motor and blower should be
checked. Discharge NRV should be
periodically checked for proper
functioning. Safety valve setting should
be checked periodically
Boiler Bed and Loop Seal
During every long shutdown of the boiler,
the boiler bed should be completely
cleaned; all the bed nozzles are to be
cleaned with compressed air. DP study to
be carried out to compare the values with
the initial values obtained during
commissioning of boiler. If required
further cleaning to be carried out to
obtain the DP reading nearer to the
original values.
The bed ash in lift and down legs is to be
cleaned completely, after completion of
cleaning the nozzles are to be inspected.
Wall seal blower to be operated for about
an hour and nozzles to be checked for
proper air flow through the holes. If any
of the nozzles are found chocked, the
same should be cleaned. After completion
of this checking, the wall seal blower to be
stopped and bed ash to be filled up to the
spillover portion level in lift and down leg.
After filling bed ash the wall seal blower
to be run again to check fluidization of
material inside. The settings of the wall
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
seal blower line valves should not be
disturbed.
Return leg wind box drain should be
opened and checked for any
accumulation of ash inside. If any
material is present, it is to be cleaned and
the drain to be closed again.
Stripper Cooler
During every shutdown, stripper cooler
inside material must be cleaned.
Solid transfer line should be cleaned
completely and the air slide plates in the
solid transfer line to be inspected, if any
deflection found, it is to be adjusted.
If any bed ash is present inside, it is to be
cleaned completely.
Passages between section to section
should to be completely cleaned.
Wind box of stripper cooler to be checked
for any accumulation of bed ash inside.
Air line in stripper cooler to be cleaned
from the nipple provided at the bottom.
Rotary air lock passage to be checked for
any foreign material and it is to be
cleaned.
Solid transfer line to be inspected for
intactness of refractory inside. If
refractory inside is loose or if it has got
removed, the same should be applied.
Physically check the flow of air through
air slides of solid transfer line by opening
the mobilizing air. In case any obstruction
is observed, same is to be cleaned.
Wind box of solid transfer line to be
checked for any accumulation of bed ash,
if any accumulation is found, it is to be
cleared using the plug provided at the
bottom.
Bed Pressure Transmitters
Bed pressure transmitters are to be
checked for zero indication when there is
no bed material in the bed and fans are in
stop condition. If there is any change
from zero indication the pocket mouth
should be checked for any possibility of
Section 10, Page 22
 Comm/ JB No 0993/C10
Rev 00 01/ 01.07.13
Isgec Heavy Engineering Ltd.

chocking and if any chocking is there, it

is to be cleaned.
Bed pressure transmitters have to read
pressure of bed material in fluidizing
furnace. In case a conventional impulse
line is used it will get choked with bed
material within no time. To avoid this, a
purging air is provided in the impulse line
with a constant air flow to prevent the
back flow of bed material in the impulse
line. The air flow thru this purge line is
set when the boiler is not in operation
and there is no bed material inside and
no fans are running. The air must be
sufficient that it prevents back flow. This
will be adjusted by the commissioning
engineer. After adjustment, the flow
control valve/ rotameter must be locked
and no further changes are allowed. Now
the transmitter will start showing some
reading, depending on length of line and
flow thru it. This value is to be made
ZERO with the help of HART
communicator. The indicated values
before zero setting should be recorded for
future reference. Now the bed
transmitters are ready for putting into
service

1 X 80 TPH CFBC Boiler Section 10, Page 23

M/s. PT Tereos FKS, Indonesia