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I would like to ask some questions regarding the regular inspection of boilers

2011-07-13View Original

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One of the organic heat carrier boilers in our factory is due for a routine inspection – it’s exactly 6 years old now – and a hydrostatic test needs to be carried out. I would like to ask: what is the scope of this hydrostatic test? Is it only conducted on the boiler itself? Should the pipelines in the workshop still be included? 600,000 kcal small oil furnace
Reply #22011-07-13
The inspected entity should carry out the following preparatory work in advance; 1 Factory data of the boiler under inspection, technical documentation for its installation, annual inspection reports, registration certificates for use, records of operation, maintenance and repair of the boiler, etc ; 2 The operation certificates for the boiler operators must be prepared ; 3 Open all access doors and openings on the boiler, such as manholes, handholes, inspection holes, and ash doors, and ensure that the interior of the boiler is fully cooled (below 35°C) and well-ventilated ; 4. Remove the soot and slag from the furnace chamber and flue, and take samples of the organic heat carrier in use for inspection by the inspector ; Inspection items: Boiler factory documentation, boiler installation documents, documents from the period of use, inspection reports over the years, operation and maintenance records, and the operator’s certification. Inspection of the boiler body: Check the boiler drum (shell) for any residual carbon on its inner surface, as well as for cracks or other defects on the inner and outer surfaces, at the weld joints, and in the heat-affected zones. When necessary, surface testing or other inspection methods should be employed to determine whether there are cracks or severe deformations in areas subject to high-temperature radiation and significant stress. Pipe inspection: Check for severe corrosion and wear; thickness measurement should be carried out if necessary ; There should be no severe deformation; the increase in the diameter of carbon steel pipes shall not exceed 3.5% of their original diameter, and the local height variation shall not be more than 3 mm. For straight sections of water pipes, the bending deformation shall not exceed 2% of their length or their diameter. Regular testing of organic heat carriers: The residual carbon, acid value, viscosity, and flash point of organic heat carriers in use should be analyzed annually. If two of these tests yield unsatisfactory results, or if the proportion of decomposed components in the heat carrier exceeds 10%, the heat carrier should be replaced or regenerated. Analysis of indicators such as carbon residue, viscosity, flash point, and acid value of organic heat carriers ; Inspection of the expander ; Inspection of organic heat carrier storage tanks ; Inspection of the boiler piping system; inspection of valves and circulation pumps. 1. Shut-off valves should be installed on the inlet and outlet pipes of organic heat carrier boilers. When the distance between the pump and the boiler is no more than 5 meters, a shut-off valve is not necessary at the inlet ; 2. Leak-proof sealing materials should be used at the valve connections; asbestos products are not permitted ; 3. Organic heat carrier boilers and their piping systems should be equipped with a sufficient number of exhaust valves at the highest points, so that the gas products generated during operation can be regularly discharged from the entire boiler system ; 4. For gas-phase furnaces operating independently, each furnace should generally be equipped with 2 supply pumps, one being the working pump and the other the backup pump. For vapor phase furnaces in which the condensate can flow back automatically, a supply pump is not necessary ; 5. The circulation system of the liquid-phase furnace shall be equipped with at least 2 electric circulation pumps, one serving as the working pump and the other as the standby pump. The selection of the flow rate and head of the circulation pump should ensure the necessary flow velocity of the organic heat carrier in the organic heat carrier furnace ; 6. A filter should be installed at the inlet of the circulation pump, and the filter should be cleaned regularly. Inspection of safety accessories and pressure relief valves ; Inspection of pressure gauges ; 1. Temperature measurement and recording instruments should be installed on the gas or liquid organic heat carrier transmission pipelines at the outlet of the organic heat carrier furnace, near the furnace and in front of the stop valve ; 2. When the thermal power of an organic heat carrier furnace does not exceed 2.8 MW, only a temperature display instrument is required ; 3. A temperature display instrument should be installed at the inlet of the liquid-phase furnace circuit. Hydraulic test: 1. The hydraulic test is carried out every six years, and it applies to liquid-phase furnaces ; 2. Organic heat carrier boilers should not be subjected to hydrostatic testing ; 3. The pressure for the hydraulic test is 1.5 times the operating pressure ; 4. The inspection areas for pressure testing are mainly used to check non-welded joints, such as the seals of various holes, as well as the connections of various flanges and valves. Pressure testing pump, pressure gauge for recording; airtightness test. 1. Primarily carried out for organic heat carrier vapor-phase furnaces ; 2. The test pressure is the operating pressure ; 3. The test medium is nitrogen (N2) ; 4. The main areas it inspects are the seals of various holes, as well as the connections of various flanges and valves.
Reply #32011-07-14
Reply to 2# Waiter: In which standard is specified the reason why \"organic heat carrier boilers should not undergo hydrostatic testing\"?

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