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Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos employees.
Any material contained in this document which is not already in the public
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parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Mechanical
File Reference: MEX-104.05
Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Section
Page
INFORMATION ............................................................................................................... 3
STANDARDS .................................................................................................................. 3
Saudi Aramco Engineering Standards (SAES)..................................................... 3
Other Saudi Aramco Standards............................................................................ 3
Industry Standards ............................................................................................... 3
PREPARATION FOR INSPECTION ............................................................................... 4
EXTERNAL BOILER INSPECTION ................................................................................ 6
Ladders, Stairways and Platforms ........................................................................ 7
Air Ducts and Flue Gas Ducts .............................................................................. 8
Support Structure and Boiler Casing .................................................................... 8
Stack .................................................................................................................... 9
Boiler Piping ....................................................................................................... 10
Instrumentation................................................................................................... 10
Paint and Insulation ............................................................................................ 10
INTERNAL BOILER INSPECTION................................................................................ 11
Safe Entry........................................................................................................... 11
Fans ................................................................................................................... 12
Firebox Refractory and Insulation....................................................................... 12
Burners ............................................................................................................... 13
Convection Section............................................................................................. 13
Tube External ..................................................................................................... 14
Boiler Steam/Mud Drum ..................................................................................... 17
Inspection Tools ................................................................................................. 18
Tube Internal ...................................................................................................... 18
HYDROSTATIC PRESSURE TEST.............................................................................. 19
Purpose .............................................................................................................. 19
Preparation ......................................................................................................... 20
Testing................................................................................................................ 21
CORROSION RATES ................................................................................................... 22
Example Problem 1 ............................................................................................ 23
Remaining Life.................................................................................................... 23
Example Problem 2 ............................................................................................ 24
PZV SAFETY RELIEF VALVES .................................................................................... 25
Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
List of Figures
Figure 1. Caustic Corrosion.......................................................................................... 14
Figure 2. Internal Chemical Deposits ........................................................................... 15
Figure 3. Boiler Steam Drum Inspection....................................................................... 17
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
INFORMATION
STANDARDS
The following standards define the conditions that must be met
by inspections, pressure testing and chemical cleaning of
boilers.
SAES-A-005
SAES-A-007
SAES-J-600
GI 447.002
GI 447.003
GI 402.001
SAEP-1025
SAEP-1026
Industry Standards
ASME Section 1
NBIC
API RP 572
API RP 573
API RP 574
API RP 576
Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Boiler Log
Maintenance Records
Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Stack
Boiler piping
Instrumentation
Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Stack
Stacks have been known to collapse when allowed to
deteriorate.
Deposits that accumulate in the stack can be explosive.
Deposits should be removed occasionally.
Inspect brick, concrete, and steel stacks for conditions that may
weaken these structures. Use field glasses to inspect high
stacks from the ground. Use infrared temperature
measurements to look for hot spots that would indicate internal
refractory problems.
Conduct a thorough hammer testing of the steel stacks. Pay
particular attention to the seams, stiffening rings, lugs, and
nozzles. Acids in the flue gas that may condense may attack the
upper cool portion of a stack.
Inspect bolts at the base and at elevated sections for loosening
and breakage. Check a loose bolt for abrasion from movement
of the structure. Inspect guy lines for corrosion. Inspect lightning
rods and grounding cables to see that they are securely
grounded and not corroded. Guy line connections to the
deadman at the bottom, and at the top are especially subject to
corrosion due to moisture settling retained around these
connections. Guy wires should be replaced at safe intervals,
since inspection is impractical between the deadman and the
top. The electrical resistance of the ground should be less than
25 ohms.
Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Boiler Piping
A leak or failure in a piping system may be a major problem or a
minor inconvenience, depending on the location and service.
Study historical records to determine which sections may be
approaching retirement thickness. Inspect all lines including
vents, drains, fuel supply lines, steam atomizing lines and fuel
smothering steam piping.
Inspect piping supports, and spring hangers for external
corrosion, distortion, damage, settlement or movement of the
foundation.
Inspect for internal corrosion, using ultrasonic testing. X-ray
and/or inspect internally when the lines are opened. Ultrasonic
inspection may not detect pitting, which is why internal visual
inspection is important.
Instrumentation
Inspect all lines to instrumentation for leakage. Inspect all
control valves for leakage. Verify if any safety devices or alarms
are bypassed. Alarm and shutdown settings should be verified
when possible.
Inspect water glasses, since these are extremely important in
operating the boiler. Make sure they are well lit. Have the
operator blow down the water gage in a normal manner and
observe how the level returns. A sluggish response may
indicate an obstruction in the pipe connections to the boiler.
Check pressure gages in the field against those in the control
room. Test the pressure with a test gage.
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Safe Entry
Entry into a boiler is not safe until the following have been done:
The boiler has been purged and tested to be free of fuel and
flue gases.
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Fans
Both forced and induced draft fans should be inspected when a
boiler is shutdown. The inspection should include:
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Burners
Inspect burners when unit is operating. Necessary adjustments
should be brought to the attention of the person responsible.
Defective burners should be repaired or replaced. Burners
should be inspected for cracks and plugging of orifices. Burner
tiles should be inspected for cracks and breakage.
Convection Section
The convection sections include the tube nests of downcomer
tubes, the superheater and the economizer.
The convection section should be inspected for the following:
a.)
b.)
c.)
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Tube External
The tube thickness should be measured by ultrasonic thickness
measurements. Ultrasonic measurements give a good average
thickness but do not necessarily detect pitting.
At times, it may be necessary to take tube samples to verify the
thickness measurements and to look for internal deposits and
pitting.
An example of severe corrosion due to caustic attack is shown
in Figure 1.
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Welds should be visually examined for cracking. Some weld xrays may be done.
Magnetic particle inspection and liquid dye penetrant
inspections are used to locate small surface cracks especially in
austenitic stainless steels.
Tubes should be examined at support points for excessive wear
and binding. Supports should be examined for corrosion,
cracking and damage, to make sure that they are operating
properly.
Tubes should be examined for overheating. This may be
indicated by bent tubes or excessive oxidation scale on the
tubes. Areas with excessive oxidation scale should be carefully
examined for corrosion. These may also be indications of
overheating of the tubes.
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Boiler steam and mud drums and the tube ends are inspected
for corrosion and deposits. Ultrasonic thickness measurements
are made on the drums.
Inspect tube ends for proper projection and flaring as well as
mechanical condition.
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Inspection Tools
Pitting may not always be detected by ultrasonic measurements
that measure the average thickness of the metal. Pit gage
measurements may be required. Some fiberscopes are
equipped to measure pits.
Cracking may require liquid dye penetrant and /or magnetic
particle to reveal the extent of cracking.
Tube Internal
Internal inspection of tubes is done to look for corrosion, pitting,
cracking and scale deposits. Tube ends can readily be
inspected while inspecting the drums.
Without taking tube samples, internal inspection of the tubes is
limited to the length (maximum of 100) of a fiberscope type of
instrument called a bore scope. A bore scope can give a view or
a TV picture of the inside of the tubes. Some fiberscopes are
equipped to measure pits. Fiberscopes are limited in that they
cannot detect build up of iron oxide inside the tubes. Even
massive deposits of hard dense iron scale can appear to be
clean metal surface.
Procedures for tube section removal and evaluation of scale
density must be carefully followed to obtain valid results.
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Pressure test
Any test where hydrostatic or pneumatic pressure is
applied to test equipment.
Strength test
Pressuring the vessel or piping beyond its normal
operating pressure.
Tightness test
Pressuring a vessel or piping to its operating pressure
and checking for leakage.
Purpose
The purpose of a hydrostatic test is to determine if the
equipment will sustain a strength test and a tightness test.
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Preparation
Preparation for a hydrostatic test include:
Determine if the proper gages are being used for the test.
Verify that the proper test fluid requirements and the proper
test gages are available.
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Testing
The test procedure for each particular boiler should be followed.
Any deviation from the test procedure should have the proper
approval.
In general, the test procedure specifies:
Filling with test fluid. Care must be taken to vent out all the
air as much as possible, and fill from the bottom. The fluid
used is usually water with inhibitors. Use of the proper test
fluid is especially important when the heater contains
stainless or high alloy steels. Close all vents, once filling is
complete.
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
CORROSION RATES
A corrosion rate is determined using two measurements of wall
thickness taken over a period of time.
C =
tO - t A
x 1000
Time
where: C
tO
tA
Time
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Example Problem 1
In October 1995, the wall thickness was 1.181 in. In April 1998, the wall thickness was
1.135 in. What is the corrosion rate?
C =
Time =
C =
C =
tO t A
Time
1000
30 months
2.5 years
0.046x1000
2.5
Remaining Life
The remaining life calculation uses the remaining corrosion allowance and corrosion
rate.
RL =
where:
RCA x 1000
C
RL
RCA
The remaining corrosion allowance is simply the last measurement minus the minimum
thickness.
where:
RCA
= t A - t min
tA
tmin
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Example Problem 2
In the last sample problem, if the minimum thickness was 1.095 in., what is the
remaining life?
Since corrosion rates are not always constant, an inspection should be scheduled
sooner than the 2.1 years of remaining life. If the corrosion rate can be checked on line,
it should be scheduled for about th of the remaining life. If a turnaround is required,
the next inspection should be about of the remaining life. If RL limits the run length
before the next turnaround, replacement of the equipment should be evaluated.
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Bench Test
The ASME code requires testing of boiler PZVs once per year.
This test is done by shutting down the boiler and removing the
PZVs. The PZVs are tested on a test bench. The PZV should
pop within the lesser of 10 psi or 3% of the relief setting. The
PZV should close tightly at no less than 96% of the set pressure
(4% below set pressure).
Check the safety relief valve records to make sure GI 447.003
and ASME Section 1 requirements are met.
The boiler safety relief valves are tested in-place annually. A
visual inspection that includes a check for leakage and vibration
damage should follow each operation of the safety relief valve
An approved written procedure must be in place to test safety
relief valves on-line.
A qualified and certified PZV technician performs testing and
inspection. Bench test and inspection is documented in the PZV
Maintenance Report Form 3750. Both pop and leak tests are
performed on the bench. Disassembly and inspection of the
PZV is required at the third consecutive PZV operating interval
(3 years for boilers).
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Pressure Test
All boiler PZVs must be tested in place for the final set pressure
and blowdown (reseating) adjustments as required by the
ASME code. The in-place test is performed as per a written
approved operating procedure. The in-place test has provisions
to prove full lift capacity and accuracy of adjustments. The inplace test is reported on the same form 3750 as the bench test.
Additional in-place pressure tests may be required for boilers
over 400 psig depending on operating experience as
recommended by the National Board Inspection Code. The
National Board Inspection Code recommends testing boilers
less than 400 psig every 26 months.
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Recommended Action
250-500 g/m2
500-1000 g/m2
Recommended Action
10 g/m2 or less
Excellent
Good
Average
Passing
>50 g/m2
Not Acceptable
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Steps
The procedure for chemical cleaning of boilers at the Abqaiq
Utilities Plant is attached as Addendum B. This procedure is
typical of chemical cleaning procedures since it follows General
Instruction GI 402.001.
The boiler chemical cleaning procedure is divided into the
following sections:
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Preparation
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
WORK AIDS
WORK AID 1:
In October 1996, the wall thickness was 1.181 in. In April 1998, the wall thickness was
1.135 in. What is the corrosion rate?
C =
Time =
C =
C =
tO t A
Time
1000
30 months
2.5 years
0.046x1000
2.5
The remaining life calculation uses the remaining corrosion allowance and corrosion
rate.
RL =
where:
RCA x 1000
C
RL
RCA
Part 2
In the last sample problem if the minimum thickness were 1.095 in., what is the
remaining life.
RCA = 1.135 - 1.096 = 0.039 in.
RL =
RL = 2.1 yrs.
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
GLOSSARY
austenetic
design pressure
fiber scope
fluxing
maximum allowable
pressure
neutralization and
passivation
PZV
Safety valve.
scale
slagging
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Engineering Encyclopedia
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
ADDENDUM
Section
ADDENDUM A:
ADDENDUM B:
ADDENDUM C:
ADDENDUM D:
Page
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Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
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Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
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Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
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Boiler Inspection, Pressure Test and Chemical Cleaning
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Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
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Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
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Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
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Introduction to Boilers
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Boiler Inspection, Pressure Test and Chemical Cleaning
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Boiler Inspection, Pressure Test and Chemical Cleaning
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Boiler Inspection, Pressure Test and Chemical Cleaning
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REFERENCES
SAES-F-008
SAER-5440
GI 402.001
ASME Boiler and Pressure Vessel Code
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