TOA

TOA

Inspection points of Genex No.1 Boiler

TOA OIL CO. LTD. Keihin Refinery

 TOA
TOA Specification

-Single drum, Convectional reheating, natural circulation type (no

building)
-Evaporation (maximum continuing rating=MCR):630t/h
-Reheating steam flow:460t/h
-Design pressure:19.10MPa
-Operating pressure(MCR)
Super heater outlet: 17.06MPa
Re-heater inlet: 3.48MPa
Re-heater outlet: 3.31MPa

TOA OIL CO. LTD. Keihin Refinery

 TOA
TOA Specification

-Operating temperature(MCR)
Super heater outlet: 541deg.C
Re-heater inlet: 320deg.C
Re-heater outlet: 540deg.C
Economizer inlet: 242deg.C
Air temperature: 15deg.C
-Combustion type
-Refinery by-production gas (LCG, HCG) and vacuum oil residue co-
combustion
-Fuel oil combustion(only emergency)

TOA OIL CO. LTD. Keihin Refinery

 TOA
TOA Specification

-Balanced draft
-Dimension of Boiler
9,590mmL×12,530mmW×40,700mmH
-Heated surface area
-Evaporator tubes (Water wall tubes and screen tubes):2,290m2
-Super heating tubes(Roof, Back wall, 1stS.H.,2nd S.H.
3rdS.H.):4980m2
-Re-heating tubes:2,350m2
-Economizer tubes:3,090m2
TOA OIL CO. LTD. Keihin Refinery
 Support system
TOA
TOA

Steam drum

2nd R.H. 1st R.H.

3rd S.H. 1st S.H.

2nd S.H. Eco.

Fire box

Side view Water and steam circulation drawing

TOA OIL CO. LTD. Keihin Refinery

TOA
TOA
Steam drum

Check point Reason Repair &Inspection

Cracking of the weld of Thermal fatigue by shut VT,PT,MT
nozzles to drum. down and start up
-Grinding (allowable
thickness)
-Weld (no allowable
thickness)

VT: Visual Testing

PT: Dye Penetrant Testing
MT: Magnetic particle Testing

TOA OIL CO. LTD. Keihin Refinery

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TOA
Steam drum
Steam outlet nozzles Man hole nozzles

Nozzles for down comer

Crack

Shell of drum

Nozzle

TOA OIL CO. LTD. Keihin Refinery

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TOA
Steam drum

Check point Reason Repair

Water surface level Corrosion by weld (no allowable

corrosion dissolved oxygen(DO) thickness)

TOA OIL CO. LTD. Keihin Refinery

TOA
TOA
Steam drum

Water surface
level

TOA OIL CO. LTD. Keihin Refinery

 TOA
TOA
Fire box
Water wall tubes and generating tubes

Check point Reason Repair &Inspection

Bulging , especially near Abnormal Scales adhesion -Wall thickness

burners and at the inside wall and locally measurement by
burners installation level bulge. Generally it Ultrasonic(UTM)
occurred at high heat flux -Taking samples
tubes.

UTM: Ultrasonic wall Thickness Measurement

TOA OIL CO. LTD. Keihin Refinery

TOA
TOA
Fire box

Tubes near burners Water wall tubes in

and at the burner back of fire box
installation level

Burners
(front and back
of firebox)

Water wall
tubes in front
of fire box

Water wall tubes in

side of fire box

TOA OIL CO. LTD. Keihin Refinery

 TOA
TOA
Fire box
Water wall tubes and generating tubes

Check point Reason Repair &Inspection

Alignment Non-uniform temperature -Measurement of the

Bowing between the tubes lead to outside diameter
the distortion and -Taking samples to
bowing. check their
microstructure

TOA OIL CO. LTD. Keihin Refinery

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TOA
Fire box

Screen tubes

Water wall tubes in

back of fire box

TOA OIL CO. LTD. Keihin Refinery

 TOA
TOA
Fire box
Water wall tubes and generating tubes

Check point Reason Repair &Inspection

Refractory of To ensure stable -Replacement of the refractory
burner throat flame -Small extent repair has the risk of
falling down

TOA OIL CO. LTD. Keihin Refinery

TOA
TOA
Fire box

Water wall
tubes Burner
throat

Burners
(front and back Refractory
Front side of Back side of the of fire box)
the boiler boiler

TOA OIL CO. LTD. Keihin Refinery

 TOA
TOA
Fire box
Water wall tubes and generating tubes

Check point Reason Repair &Inspection

Samples from the -Prediction of timing of If the chemical cleaning is

tubes and the chemical cleaning necessary, the specification
investigation the -Adequate water treatment will be decided with the
scales composition dissolving test
and amount

TOA OIL CO. LTD. Keihin Refinery

TOA
TOA Fire box

Sampling tubes Water wall tubes in

near burners and at back of fire box
the burner
installation level

Burners
(front and back
of firebox)

Water wall
tubes in front
of fire box

Water wall tubes in

side of fire box

TOA OIL CO. LTD. Keihin Refinery

 TOA
TOA Fire box
Water wall tubes and generating tubes

Check point Reason Repair &Inspection

Inspection hole of header is -Lower water wall headers -Analysis of the

opened
-The scale amount and
distribution of the inner
surface is checked.
-Corrosion and erosion is
inspected
are particularly susceptible deposit
to heavy deposit buildup.
-To check the adequate
water treatment

TOA OIL CO. LTD. Keihin Refinery

TOA
TOA
Fire box
Water wall tubes inlet header in
side of the boiler

Water wall tubes

inlet header in back
of the boiler

Water wall tubes

inlet header in front
of the boiler

TOA OIL CO. LTD. Keihin Refinery

TOA
TOA Super heater/Re-heater

Location Check point Reason Repair &Inspection

Header -Header stub weld -Cracks -PT,VT

(Penetration zone of (Restraint of thermal -Grinding (allowable
Water wall) expanding restraint) thickness)
-Weld (no allowable
-Cracking of the weld Thermal fatigue by thickness)
shut down and start up

TOA OIL CO. LTD. Keihin Refinery

TOA
TOA Super heater/Re-heater
Header

Header
Crack

Stub
Stub
zoom
2nd R.H. 1st R.H.
Header to stub weld

1st S.H.
3rd S.H.
Nozzles of
header Header
shell
2nd S.H.

Crack

S.H. and R.H. outlet headers

TOA OIL CO. LTD. Keihin Refinery

TOA
TOA Super heater/Re-heater

Location Check point Reason Repair &Inspection

Tubes -Outer surface -High temperature If needed, protector

condition is inspected oxidation is installed
visually -Drainage attack
-Wall thickness from soot blower
measurement, outside
diameter
measurement
Alignment -Drainage and -Measurement of
Color changing deposit in the tubes the outside
causes the expansion diameter
difference between
tubes
-Misalignment,
bowing, and color
changing

TOA OIL CO. LTD. Keihin Refinery

TOA
TOA Super heater/Re-heater

2nd R.H. 1st R.H.

3rd S.H. 1st S.H.

2nd S.H.

TOA OIL CO. LTD. Keihin Refinery

TOA
TOA Super heater/Re-heater

Check point Reason Repair

&Inspection
-Stainless steel to Cr-Mo -Cracks and excessive weld deposit VT,PT
steel weld, especially (Dissimilar weld , Carbon transfer,
HAZ of Cr-Mo steel difference of the thermal expansion)

TOA OIL CO. LTD. Keihin Refinery

 TOA
TOA Super heater/Re-heater

309 Weld
metal
Crack
Outside

Inside 304H
2nd S.H.
SA213T22

Dissimilar weld

TOA OIL CO. LTD. Keihin Refinery

TOA
TOA Super heater/Re-heater

Location Check point Reason Repair &Inspection

Attachment of the tubes -Deterioration -High -Penetration

and stick of temperature test(PT) of the
slide spacers, oxidization and weld.
tie lugs combustion ash -Removing the
plugging plugged ash
-Tie lugs, tie -Different -Visual inspection
rods, slide thermal -PT
spacers weld expansion
-Stress
concentration
-bent tubes -If the bent tubes Tie rods, tie lugs
deformation are restrained, weld will be
deformation inspected for the
occur there. cracking
occurrence.
TOA OIL CO. LTD. Keihin Refinery
TOA
TOA Super heater/Re-heater

Fillet weld
Tube

Tie lug

Crack

Attachment of the tubes

(In the case of tie lug)

TOA OIL CO. LTD. Keihin Refinery

TOA
TOA Super heater/Re-heater
Location Check point Reason Repair
&Inspection
Sprays to control Dismantle the Thermal fatigue, VT,PT
temperature sprays and check Thermal shock ,
the sprays and the vibration will
piping give damages to
them.

Anti- vibration plate If this plate has -High VT

burning damage, it temperature Replacement
is required to oxidation
determine whether -If supporting
it can withstand system breaks,
until next T/A or the vibration
not. will be caused
by flue gas.

TOA OIL CO. LTD. Keihin Refinery

TOA
TOA Super heater/Re-heater

Sprayed Water

Piping
Nozzle

Steam

Deterioration Inserted spray nozzle

Water spraying device

TOA OIL CO. LTD. Keihin Refinery

TOA
TOA Economizer
Location Check point Reason Repair &Inspection

Tubes -Inspection of the -The vibration from -No gaps between

area of contact the passing of the tube bank supports
between tubes and flue gases causes the and tubes
supports defect and abrasion -area of contact get
-inside banks are as large as possible.
difficult to watch
-Tubes outer surface -Erosion occur at the Economizer is low
condition near soot high flue gas temperature, so
blower velocity area by lowering of the
drainage of soot material strength
blower doesn’t exist, and
the cause of rapture
is almost the
erosion.
So, only weld
repair is needed.
TOA OIL CO. LTD. Keihin Refinery
TOA
TOA Economizer

Soot bower

Economizer

TOA OIL CO. LTD. Keihin Refinery

TOA
TOA Boiler support system

Location Check point Reason Repair &Inspection

Hunger -Check the loading to Stress relaxation of Comparison with
the rods evenly. the piping system , the initial value of
Vibration -looseness, uneven ground them.
absorber deformation, subsidence causes
breaking the stress
distribution change
to the hunger
system.
Tube banks -Check the weld of Fracture, looseness It is not prefer to
hunger system the member, bolt & generated by the tighten the
at ceiling nut, hunger rod restrain of the loosened hunger.
looseness expansion and After to find the
unexpected stress cause and remove
it, re-setting should
be done.

TOA OIL CO. LTD. Keihin Refinery

TOA
TOA Boiler support system

Casing hunger

Tube header
hunger

Water wall tube

hunger

TOA OIL CO. LTD. Keihin Refinery