Boilers are machines that deal with high temperature and pressure in the power industry, which makes the boiler more important equipment and needed regular maintenance.
Daily maintenance of Boilers:
Things that need to be considered every 1 hour:
- Water level from the condensate tank
- Fuel oil levels from service tanks and strong tanks
- Water Cooling
- The temperature and pressure of lubricating oil from all equipment cords
Things that need to be considered every 4 hours:
- Open the drain valve air storage tank, air heater and a tank compressor
Analyze boiler feed water and boiler water every 2 hours once
- Help Burner and clean tip of the burner (if use a burner)
- Do it next to the stocker
- Perform Soot blowing.
Things that need to be considered every 8 hours:
- Do Blow Down lower drum
- Perform total cleaning throughout the boiler area
- New chemical replacement/delivery for Water boilers
Boiler Maintenance During Operation Period
Careful maintenance in the intended operating period is how to operate the steam boiler in accordance with the applicable instructions or in accordance with the design of the Boiler makers.
In addition, the use of feed water must also be appropriate or qualify as filler water for kettles. What is clear is that boiler fill water must be different from substances that can damage the boiler, both corrosion and scale.
To prevent this, external treatment and internal treatment is carried out, for example, installed a pH control on a condensate line, or Water treatment for raw water, as well as injecting a chemical in a Water feed and a Water boiler.
Boiler Maintenance after Operation Period
The first step taken after the boiler has been operating for several months and will be stored long enough is chemical cleaning and mechanical cleaning, while injecting the chemical into the boiler for chemical cleaning process, namely:
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Two days before the boiler is turned off, then the type of chemical that has been determined and the dosage starts to be injected by monitoring the pH of the boiler water should not be more than 13.
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Blow Down lower drums are routinely carried out, to get rid of dirt that settles
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After two days injecting the chemical, the boiler is activated and then the water circulation/replenishment of the filler water is carried out.
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After the boiler is cold, the boiler water is blown (emptied)
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Examination carried out by Depnaker, to determine the things that need to be carried out in the next step for example in mechanical cleaning inside and outside the boiler section.
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After cleaning both the outside and the inside where it is done by requiring time, it will be repeated by the Department of Labor, to determine whether it is still necessary to do re-cleaning or not
Inspection and Repair:
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Inspections carried out by the Department of Labor are steam drums, Water drums, Superheater Tube, cleanliness, material strength, material conditions and WaterTube. These parts are certainly associated with high-pressure parts that are very dangerous for human safety.
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Inspections carried out by the company, namely parts that are not high-pressure, which part is associated with productivity and things that interfere with the efficiency of the boiler for example on the fuel frame, boiler wall casings, impellers, dampers, insulation etc.
Hydrostatic test:
To determine that the boiler meets the requirements to be operated, a hydrostatic test is performed. hydrostatic test that is boiler compaction treatment using cold and clean water to find out and ensure that the boiler is in a state of not leaking both on the valve, packing and pipe.
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Empty the boiler, the drain valve is tightly closed, the safety valve is off, the main steam valve is closed, the vent valve steam drum and superheater are fully opened.
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Run the water feed pump with small openings, with the condition of fill water that meets the requirements.
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After the boiler water is full so that the water spills through the vent valve, and make sure that the air is gone, turn off the pump and close the vent valve.
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Run the pump specifically compaction, with a small capacity (determined), to get a pressure increase slowly
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The increase in pressure on the metadata is 10% of the working pressure.
Steam test:
This experiment is conducted to determine the workability of the safety valve according to the purpose of usage. By not exceeding the allowable pressure. This experiment is carried out at each:
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Replacement of each safeguard.
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Use of safety level using a spring.
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Safety levels that work are doubtful.
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Replacement of fuel types
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Each boiler is equipped with automatic tools