SELENGGARA DANDANG (MAINTENANCE):

1. Apa itu selenggara?

Kerja atau aktiviti yang dilakukan, untuk memastikan loji/alatan selamat dan cekap untuk
beroperasi pada kapasiti rekabentuknya

2. Jenis-jenis Selenggara
 Penyelenggaraan Pembetulan (corrective)
 penyelenggaraan pencegahan (preventive)
 penyelenggaraan ramalan (predictive)

3. Untuk sistem dandang, ia bermaksud:-

 Untuk pastikan operasi selamat oleh pemeriksaan biasa
 Untuk menjaga dandang sentiasa beroperasi
 Untuk menjaga dandang mematuhi syarat beroperasi
 Untuk memulihkan kecekapan dandang
 Untuk membaiki bahagian yang rosak dan pastikan ia kemas
 Untuk kebersihan dandang

4. Activities
 Routine service (preventive)
 Repair (corrective)
 Inspection (preventive/predictive)
 Overhaul (predictive)

5. After 5-6 months of the boiler operation, the boiler should be down for maintenance.

(1) To clean off the deposits in the drum, headers of the boiler
(2) To clean off the soot on the heating surface.
(3) Inspection on the internal or external sections of the boiler, such as check of the
welds of the pressure parts and steel sheets for corrosion. Severe defects shall be
subject to immediate remedy action. If the suspicious defects are located but not
impacting the safe operation, records shall be taken for future reference.
(4) Check the induced draft (ID) fan for bearing abnormality, check the impeller and the
casing for wears and tears. The user shall keep sufficient spare parts for the
impellers.
(5) Some portions of the boiler walls can be removed for thorough inspection, if
necessary. When the inspection locates the serious damage, the complete repair has
to be carried out before start up. All the findings from the inspection and the repairs
after the inspections shall be entered into the boiler safety technical logs.

(6) Preservation for the boiler out of service for a long time:

a. Water preservation:
fill up the boiler with the treated water, and then boil up the water to
remove the air. Fully close all the doors and openings. Or fill up the boiler
with the de mineralized water of high alkalinity to prevent the corrosion.
The chemicals added into the de mineralized water usually are NaOH
 (2kg/mᶾ) or Na₃PO₄ (5 kg/mᶾ), and that added into the boiler water are
NaOH (5 kg/mᶾ) or Na₃PO₄ (15-20 kg/mᶾ). This method is only for short time
shutdown preservation with the heating surfaces and the boiler walls
properly dried.

b. Pressure preservation:
After removal of deposits from inside the boiler, all the valves shall be
closed. Preservation solution is to be added up to the lowest point of boiler
outlet header. Heat up the boiler to create a pressure of 0.1-0.2MPa, and
then hold the pressure for 2-3 hours. After pressure is dropped down, the
preservation solution should be used again to fill up the boiler, and then
keep the pressure of 0.2MPa by using a hydraulic way. The preservation
solution is composed of caustic soda (100mg/L), phosphorus pent oxide
(100mg/L), sodium sulfate (250mg/L). During the preservation period,
regular inspection for the proper concentration of the solution is required.
When the concentration of sodium sulfate is found to be lower than 50mg/L,
more of that chemical shall be added to keep the specified concentration.

c. Nitrogen preservation(omitted)
When the boiler is down for a quite long time, the nitrogen preservation
can be applied.

6. Maintenance Boiler Cleaning

 Tube Cleaning
Used to remove waterside deposits to prevent tube failure, 2 methods available:
i. Mechanical Cleaning
Consist of a rotating cutter head driven by an air-powered motor that fits
with size inside tube

ii. Chemical Cleaning

Use 5% hydrochloric acid (HCL) solution with an inhibitor added to lessen
boiler metal acid attack. Can use 2 method of chemical cleaning:
 Circulation
 Static (Fill and Soak)
 Soot Blowing
a) Cleaning boiler tubes from deposits (incomplete combustion, rust deposits,
dusty condition, upstream sootblowing and etc) of unburned fuel elements
(soot) while boiler in operation.
b) Cleaning media could be steam, air or use of a vibrator.
c) Dirty boiler tubes can result in poor heat transfer in boiler and then reduce
efficiency.

 Testing of Boiler Water

a) Taking of boiler water samples and tested for alkalinity and contaminants.
b) Contaminanted water can lead tubes blockage, overheating and reduce
efficiency of boiler.
c) Improper alkalinity can lead to problems of corrosion.

 Draining of Condensate
a) Remove water in steam pipelines, its can lead to water hammer.
b) Steam and slug of water travel at a very high velocity hit any obstruction
downstream and can result in severe damage, for example:

 Testing/Cleaning of water gauge

a) Blowing of steam and water through the steam and water passage of gauge
glass
b) To clear any blockage which can cause false level indication
  Testing of control systems
a) Important control devices such as low water fuel cut out (LWFCO), combustion
system, safety valves and etc
b) Must be tested for their accurate operation
c) To ensure they respond as designed

7. Maintenance Inspection
 Dimensional
Erosion, corrosion, abrasive wear, deformation changes due to stress, cavitation
 Distortion
Abstructed expansion, overheating, unequal expansion, overstress
 Cracks
Fatique, thermal stress, water hammer, improper welding, poor design
 Deposits
incomplete combustion, rust deposits, dusty condition, upstream sootblowing and etc
 Blockage
Accumulation of scales, soot, foreign matter, damaged strainer
PEMERIKSAAN DANDANG (INSPECTION):

Who

Why What

Boiler
Inspection

How When

Where

Why do inspect Boilers?

 For compliance law of FMA 1967
 Safety for man and equipment
 Know condition of boiler

FMA 1967 (Notification, Certificate of Fitness And Inspection) Regulation 13 & 14

 Initial inspection conducted by Inspector

 Regular inspection every 15 month subject to such extension not exceeding 36
months by discretion of Chief Inspector

FMA 1967 (Steam Boiler and Unfired Pressure Vessel) Regulation 78

 PIC SB/UPV must notify inspector in writing, which may affect safety or strength
SB/UPV
 Loss boiler water, melting of fusible plug and tube burst
 Qualified Qualified Who Will
DOSH Insurance Authorised
3rd party owner's Do
Inspector Inspector Inspector
inspector inspector Inspection?

Check for any

abnormalities or damage
in following area: External/ Operating
Inspection
 Platform and ladders
 Insulation Non-destructive
 Skin temperature using Testing (NDT)
infrared thermography
 Any leakage/seepage
Internal
Inspection
at PSV and other
valves and flanges Jurisdiction
 Any sign of water Inspection
under insulation

What?

 Usually internal Inspection occur during

jurisdictional inspection
 Reason :
1. To note any condition that can affect the Where? What?
strength to confine the pressure
 Longitudinal seam  Crack and grooving
2. To check structural soundness of pressure
of drums  Groove at fillet
containing parts
 Unstayed heads weld
 Manholes and  Corrosion thinning
opening & crack
 Welded nozzles  Weld washout,
and attachment crack,
 Stay & stay bolts deterioration
 Waterline in drums  Crack and even
 Tubes and plate tension
expose to fire  Oil and pitting
 Tube to Shell(Weld  Bulging or
joint) blistering
 Crack/ Pitting
 HOW?
•Visual examination → to determine
surface condition of part, reinforcement
WHAT IS NDT? and undercutting of welds, alignment of
•Testing of material to detect internal and •Eddy current inspection/examination → to
surface defects without damaging material detects discontinuties in pipe and tube by
subjecting material to strong external
during test
magnetic force
•Radiographic examination → to examine
discontinuties of surface and subsurface
using radioactive source and film
•Ultrasonic examination → provides
indications of surface and subsurface
discontinuties, depth can determined
•Liquid Dye Penetration → to detect
continuties of surface being examined
•Magnetic Particle Testing → can used
ferromagnectic surface to reveal surface
discontinuties and limited degree, those
Non-destructive located below the surface
Test (NDT)
LIMITATION

 Results are normally

qualitative
WHY IS NDT IMPORTANT?  Requires highly trained and
experienced personnel
•To prevent accidents & safe human lives
•To improve product reliability
•To maintain quality level
•To lower manufacturing cost
ADVANTAGES
•Tested object can be reused
•Minimum preparation of specimen
•Can be performed during objects in service
•Portable equipment and suitable for field
inspection
How?
•Tensile Test : Specimen boiler
drum taken and put to tensile test,
usually old boilers to check
mechanical properties (ductility &
ultimate tensile strength UTS)
•Bend Test : specimen of weld
taken for bend test to check for
weld flaws

Destructive
Test (DT)

What?
• Specimen of part of boiler
taken and tested to it's limit
to destruction
• DT Method: Tensile, Bend,
Charpy, Hardness, Fatigue,
Creep, Metallography and
chemical analysis
Boiler Inspection
• FMA 1967, (Notification, Certificate of fitness and inspection)1970
• Regulation 13, 14 and 17

Furnace
• Front wall tubes including area of burner  Furnace floor area
• Side wall tubes including peephole area  Rear wall tubes including boiler nose area

Secondary Superheater & Reheater
• Secondary superheater tubes  Secondary reheater tubes  Boiler roof
• Screen tubes  Manhole and sootblower area

Heat Recover Area

• Primary superheater/reheater tubes  Manhole area  Economizer tubes
• Screen tubes  Sootblower area

Force Draft (FD) Fan Ducting

• FD fan suction screen  Hot air ducting from air preheater to windbox
• Steam air preheater area

Steam Drum  Feed pipe, girth plates,baffles,

• Drum internal surfaces  Gauge glass scrubbers, chevron driers,
• All pipe fittings/joints inside drum  Isolation valves separators
Header
• Superheater inlet and outlet header  Waterfall header
• Reheater inlet and outlet header  Economizer inlet and outlet headers

Tubes
• Cutting of tubes for inspection and rewelding
• Replacing worn-out tubes

Force/Induced Draft Fan  Casing and ducting

• Impleller and shaft  Bearing
• Suction part and impeller gap  Fluid coupling

Valves and Fittings  Feedwater control valve and its bypass  High pressure dosing valves
• All safety valves  Isolating valves of burner inlet and outlet
• MSV and its bypass  Boiler and drum blowdown valves

Economizer
•Interior tubes and headers (corrosion, oxygen pitting and scale)  Cleanliness and security of vent and drain
•Exterior tubes and headers (corrosion, erosion and deposits) connections valves
•Soot blower (impingement and leakage)  Exterior casing for leaks and tightness and doors

Water Columns  Free expand with boiler

•leaks, cleanliness and visibility of GG  Check leaks, internal deposits and missing
•Cleanliness and breakage of Iluminators, reflectors and mirror insulation piping to drum
•Operation and condition of gauge cocks and valves (pulleys and chains if used)  Check high and low water alarms and trips

Feedwater Regulator
 Check leaks, operability and cleanliness
 Do not dismantle if operation satisfactory
 Check connecting lines and mechanism for proper function
 • Burner throat refractory
• Pit refractory
Refractory • Slag build up on refractory
• Missing Insulation on
•Check extend expansion and headers and drum
contraction of pressure parts
during startup and shutdown
Furnace
•Check header support hangers
always in tension. Looseness and Casing • Burner wear by observe
indicate obstruction to free flame shape and
expansion and contraction completeness of
Burner combustion
• Ease of operation burner
•PSV dissembled and check for vanes, indicate burner
any surface discontinuity at mechanism condition
seat PSV. If any discontinuity
Pressure
presence, remove it via lapping Safety
or changing faulty internal etc Valve
•Assemble and do leak test
using method : pnuematic pop (PSV)
test/water leak test • Check for change of
Superheater pressure drop through SH,
Tubes indicating to internal
condition of tubes
•Check temperature differences
over two units at constant load.
Indicate deposits/ build up Economizer
•Check pressure drop over any part and air pre- • Check steam quality,
of system at constant load,
indicating misplaced/ bypassed
heater indicate condition of steam
baffle scrubbers and separators
Boiler
• Check noises in drums.
Drums
Maybe caused by loose
connections of drum
internal piping