135tph Boiler Unit-II Erection Report

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February 17, 2011

REPORT ON 135 TPH BOILER UNIT-II INSPECTION AT SYAM DRI POWER

LIMITED SAMBALPUR.

This is the final visit made for inspection of boiler under commissioning.

01.In FD outlet, bend duct is seen without stiffener. The stiffener should be provided to all the bendducts.

02.All ducts were seen with temporary support and expansion bellow with transportation clamp.This should be removed.

03.One of the PA line is fouling with column. The line will face chocking problem during operationtime. This should be reviewed.

04.PA line Damper operating levers were seen with bend. Because of this bend the regulation ofthese dampers is not smooth. This shall be rectified.

05.There is no approach platform for APH interconnecting duct manhole. Approach shall be madefor future inspection.

06.Economiser coil alignment was seen and it is found to be ok.07.Blow down pipe isolation valve supported by temporary support. This should be removed and

permanent support shall be given for the same.

08.Economiser inlet header was seen with temporary support. This should be removed andpermanent support shall be given for the same.

09.Pipings in HP dosing tank is found to be wrong. The Inlet pipe is connected in drain line.Realignment should be made.

10.In drum, CBD piping and HP dosing piping connection was interchanged. This was happened inboiler I and created many more super heater tubes failure. This should be rectified as shown in

photos.

11.Economiser support tie beam was seen eroded due to condensation. This was seen in boiler unit-I. This support beams should be insulated in both the boiler.

12.The idea of providing a hopper with a tapered plate was to land the bunker outlet chute onthe taper portion. This helps in loosening of coal due its pressure exerted by the coal

Column above. If the chute is above the rotor of the feeder, it compacts the coal in the feeder.

In fact the hopper should have been little bigger so that the coal column pressure fully acts

on taper plate.

13.Economiser top bank support beam was welded with tie beam by temporary angle. This shouldbe free for thermal expansion.

14.In right side water wall, near the roof fouling is found with platform. This platform will not allowthe boiler thermal expansion. This should be removed.15.The hanger rod shall have clearance at the beam hole to accommodate the deflection.

16.In bunker, horizontal stiffeners should meet with vertical columns. So that the bunker loadShall be transferred to the columns (viewed from boiler unit -I).

17.Manhole should be provided for unit-II in between the two blocks of APH. In unit-I approachplatform should be provided all the man holes in APH for future inspection.

18.In unit-II economizer is not having man hole door, but approach is available. In unit-Ieconomizer having man hole door but approach is not available. Inspection doors and approach

should be made for future inspection.


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19.ESP ladder was seen without handrail. Top level ladder are not having proper handrail. Thisshould be rectified.

20.Boiler unit I was seen without proper sealing and insulation in furnace top. All seal weldingshould be done in all seal boxes. Care should be taken to avoid this type of sealing arrangement

and insulation on boiler unit-II.

21.In ESP-II top, all corners should have canopy plate to reduce the rain water ingress inside theESP. This should be rectified.

22. In ESP hopper, there was a gap between each stiffener. All the stiffeners should be welded asRing like structure


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PHOTOS WITH COMMENTS BOILER II


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Photo 1. FD outlet bend duct is seen without stiffener. The stiffener should be provided at all the

bend of the ducts.

Photo 2. PA duct was seen with temporary support and expansion bellow with transportation

clamp. This should be removed.


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Photo 3. In PA header, one expansion bellow was seen with transportation clamp. This should be

removed.

Photo 4. One of the PA line is fouling with column. This will face Chocking problem during

operation time. This should be reviewed.


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Photo5. Photograph shows the PA line damper. Damper operating lever were seen with bend. It is

difficult to open / close. This shall be rectified.

Photo 6. In PA line, bolt & nuts in mixing nozzle connecting flange is missing.

This should be provided otherwise air leakages are possible.


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Photo 7. Burner primary air line expansion bellow was seen with transportation clamp. This

should be removed.

Photo 8. There is no approach for APH which is interconnecting duct manhole. Approach should

be made for future inspection.


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Photo 9. Economiser coil alignment was seen and found to be ok.

Photo 10. In secondary duct, Expansion bellow was seen with transportation clamp. This should

be removed.


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Photo 11. Blow down pipe isolation valve was supported by temporary support. This should be

removed and permanent support shall be given for the same.

Photo 12. Economiser inlet header was seen with temporary support. This should be removed

and permanent support shall be given for the same.


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01.Photo 13. Pipings in HP dosing tank is found to be wrong. The Inlet pipe is connected indrain line. Realignment should be made as per above comments.

Photo 14. Economiser support tie beam was seen with erosion. This was seen in boiler unit-I.

This support beams should be insulated in both the boiler.

INLET

DRAIN

OUTLET


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Photo 15. The idea of providing a hopper with a tapered plate was to land the bunker outlet

chute on the taper portion. This helps in loosening of coal due its pressure exerted by the coal

column above. If the chute is above the rotor of the feeder, it compacts the coal in the feeder. In

fact the hopper should have been little bigger so that the coal column pressure fully acts on

taper plate.

Photo 16. In boiler unit-I modification were done as per previous comment.


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Photo 17. In secondary branch, duct expansion bellow was seen with transportation clamp. This

should be removed.

Photo 18. In boiler outlet duct expansion bellow were not connected properly. Extra plate

should given for this full length of bellow.


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Photo 19.Economiser top bank support beam was welded with tie beam by temporary angle.

This should be removed for thermal expansion.

Photo 20. Economiser bottom bank support beam was welded with tie beam by temporary rod.

This should be removed for thermal expansion.


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Photo 21. In drum safety valve connection is found without fasteners. During operation safety

valve stub will be eroded quickly due to leakages.

Photo 22. In right side water wall near the roof, fouling is found with platform. This platform

will not allow the boiler thermal expansion. This should be removed.


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Photo 23. Ensure all the seal boxes full welding is done. Care should be taken to avoid air

ingress / gas leakages.

Photo 24. Guide plate should be removed here. Guide will not allow the drum thermal

expansion.


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Photo 25. The hanger rod shall have clearance at the beam hole to accommodate the deflection.

Photo 26. This type of insulation will allow the rain water inside and duct will get erosion. The

insulation realignment should be made in the form of umbrella.


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Photo 27. In boiler unit-I main steam pipe is seen with temporary support at MSSV. This

should be removed and permanent support shall be given.

Photo 28. In bunker horizontal stiffeners should meet with vertical columns. So that the bunker

load shall be transferred to the columns (viewed from boiler unit -I).


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Photo 29. As viewed from boiler front this is boiler right.

Photo 30. As viewed form boiler front this is boiler left.

HP DOSING

STUB

CBD PIPE

HP DOSING

PIPE

CBD STUB


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Photo 31. Photos showing the HP dosing and CBD piping connection details.


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Photo 32. Manhole should be provided for unit-II in between the blocks of APH. In unit-I

approach platform should be provided for all the man hole doors in APH for future inspection.


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Photo 33. In unit-II economizer is not having man hole door, but approach is available. In unit-I

economizer having man hole door, but approach is not available. Inspection doors and approach

should be made for future inspection.


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Photo 34. Photograph showing the ESP ladder without handrail. The top level ladder are not

having proper handrail. This should be rectified.

Photo 35. Boiler unit I was seen without proper sealing and insulation in furnace top. All seal

welding should be done in all seal boxes. Care should be taken to avoid this type of sealing

arran ement and insulation on boiler unit-II.


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Photo 36. Photograph showing ESP-II top. All corners should have canopy plate to avoid the rain

water ingress inside the ESP. This should be rectified.

Photo37. Photograph showing ESP-I top. All corners were seen with canopy plate. Here rain

water will goes outside the insulation.


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Photo 38. ID fan inlet duct expansion bellow was seen with transportation clamp. This should be

removed.

Photo39. In ID fan inlet duct, expansion bellow was seen without proper insulation. Here rain

water will be stored and corrosion will takes place. Insulation realignment should be made in the

form of umbrella.


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Photo40. In ESP hoppers were seen with temporary support angles inside. It l allows the storing

of fly ash in hopper. This should be removed.

Photo41. In ESP hopper, there was a gap between each stiffener. All the stiffeners should be

welded as ring like structure.


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BY,

RAMACHANDRAN.A,

17.02.2011.

VENUS ENERGY AUDIT SYSTEM.

FOR,

SHYAM DRI POWER LIMITED,

SAMBALPUR.

Documents

135tph Boiler Unit-II Erection Report