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List of activities for maintenance of boilers

4 replies [Last post]
Sat, 2005-08-13 21:18
felipe rodriguez
User offline. Last seen 19 years 15 weeks ago. Offline
Joined: 13 Jul 2005
Posts: 11
Groups: None
Hello friends ...

Can anyone provide me the activity details for maintenance/turnaround of boilers as urgent.

I’ll be oblized to get any feed back regarding maintenance/turnaround plan for boilers of a refinery.

Any additional guidelines or job knowledge also will highly help me.

Thanks
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Replies

Fri, 2005-08-26 23:28
#1
Raja Izat Raja Ib...
User offline. Last seen 13 years 30 weeks ago. Offline
Joined: 2 Jun 2005
Posts: 299
Groups: GPC Malaysia, Petro-Chem / Oil & Gas
Hi Phelip,
For your review, Maybe its could fits
1. isolate- 4hrs - 4 fitter, 4 helper
2. preparation for entry - 2hrs - 2 Operation personnel
3. install scaffolding - 6hrs - scaffolders
4. open access door - 2hrs - 3fitter, 3 helper
5. Prepare & Test Tubes Drum to 50 barg -60hrs - 3fitter, 3helper
6. Acoustic Emission Testing - 30 hrs - operation Inspector
7. Open Manholes at steam drum and Mud drum - 1hrs- 1 fitter, 2helper
8. initial inspection and deposit sampling - 2hrs - 2
ech Tech
9. remove all valve and PSV and sight glass service - 20hrs - 6 fitter, 3helper
10 remove steam drum internal assembly- 5hrs - 3fitter, 3 helper
11.clean burner and burner tip - 4hrs - 3 fitter, 3helper
12. valve inspection - 2 hrs - 2inspector 2 helper
13. internal cleaning steam drum - 5hrs- 3 fitter, 3 helper
14. inspection Visual, MPI, on weldments,5hrs 2inspector
15. overhaul PSV and all valve.- 40hrs -8 fitter, 4helper
16. (DOSH)safety Inspection- 2hrs - Dosh Inspector
17. Contigency repair 2hrs - 3Fitter, 3helper
18. Refit internal steam Drum - 5hrs - 3fitter, 3 helper
19. Refit valve - 3 hrs -3 fitter, 3helper
20. refit boiler sight glass- 2hrs - 3 fitter 3 helper
21. refit all valve and PSV - 20 hrs - 6 fitter - 3 helper
22. Close Manhole at Steam / Mud Drum- 1hrs- 3 fitter, 3 helper
23. Prepare hydrotest tubes and drum - 60 hrs - 3 fitter, 3 helper
24. Repaint Boiler Casing on defect surace - 2 hrs - 2 Painter
25. remove ladder entilator and lighting 1 hrs - 1 fitter, 2 helper
26. close all access doors - 1hrs - 1 fitter, 1 helper
27. final inspection. - 2hrs - 2 inpection
28 remove isolation.- 3hrs - 5 fitter, 5 helper
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Fri, 2005-08-26 15:51
#2
felipe rodriguez
User offline. Last seen 19 years 15 weeks ago. Offline
Joined: 13 Jul 2005
Posts: 11
Groups: None
Thank you very much Bernard and Raja for your kind and important help. Now, I’d like to know about the resources for this type of job. Thank you in advance.
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Sun, 2005-08-14 08:37
#3
Bernard Ertl
User offline. Last seen 10 years 2 weeks ago. Offline
Joined: 20 Nov 2002
Posts: 757
Groups: Petro-Chem / Oil & Gas, TURNAROUND & SHUTDOWN (T/A & S/D)
There are different types of boilers. Here’s a quick task list for an ABCO volcano type boiler (produced with eTaskMaker) assuming some re-tubing and refractory replacement are needed:
  • Deliver scaffolding to site
  • Erect scaffold
  • Deliver blinds to site
  • Block & bleed, blind LPG, lock & tag
  • Open manway to firebox
  • Open mud drum and steam drum both ends
  • Inspect inside both drums
  • Deliver air movers
  • Install air movers
  • Cool down boiler
  • Obtain entry permit
  • Provide temporary lighting
  • Remove throat and brick wall
  • Deliver refractory materials to site
  • Install new throat
  • Repair brick wall
  • Cure throat refractory
  • Cut & pull (#) tubes
  • Obtain hot work permit
  • Deliver new tubes to site
  • Fit, bevel and prepare to weld new tubes
  • Mobilize welding machine
  • Tack & weld new tubes
  • X-ray tube welds
  • Mobilize hydrotest pump
  • Install test blinds
  • Hydrotest new tube welds
  • Demobilize welding machine
  • Remove hydrotest blinds
  • Demobilize hydrotest pump
  • Finish lower and upper refractory
  • Inspect refractory repairs
  • Refractory cure time
  • Inspect and mark B/O refractory
  • Chip out B/O refractory
  • Clean out debris
  • Deliver anchors, refractory and mixers
  • Install refractory anchors
  • Install refractory
  • Refractory cure time
  • Remove mixer and clean up
  • Lock and tag fuel and electric blower, blind LPG
  • Obtain entry permit
  • Open fireside manway
  • Cool down
  • Provide temporary lighting
  • Clean inside with wire brushes
  • Vacuum our dust and debris
  • Inspect boiler fireside
  • Remove temporary lighting
  • Close fireside manway
  • Remove lock & tag
  • Close manway to firebox
  • Close mud drum & steam drum both ends
  • Unblock, unblind LPG, remove lock & tag
  • Clean up work area outside boiler
  • Dismantle scaffold
  • Return scaffolding to laydown area
Bernard Ertl
eTaskMaker Project Planning Software
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Sun, 2005-08-14 00:28
#4
Raja Izat Raja Ib...
User offline. Last seen 13 years 30 weeks ago. Offline
Joined: 2 Jun 2005
Posts: 299
Groups: GPC Malaysia, Petro-Chem / Oil & Gas
this is some actvities...u can used, any how u have to recheck again and liase with your specialist to reconfirm.
Just for your idea and review. Maybe its not suit with your boiler.
1. isolate
2. preparation for entry
3. install scaffolding
4. open access door
5. Prepare & Test Tubes Drum to 50 barg
6. Acoustic Emission Testing
7. Open Manholes at steam drum and Mud drum
8. initial inspection and deposit sampling
9. remove all valve and PSV and sight glass service
10 remove steam drum internal assembly
11.clean burner and burner tip
12. valve inspection
13. internal cleaning steam drum
14. inspection Visual, MPI, on weldments,
15. overhaul PSV and all valve.
16. (DOSH)safety Inspection
17. Contigency repair
18. Refit internal steam Drum
19. Refit valave
20. refit boiler sight glass
21. refit all valve and PSV
22. Close Manhole at Steam / Mud Drum
23. Prepare hydrotest tubes and drum
24. Repaint Boiler Casing on defect surace
25. remove ladder entilator and lighting
26. close all access doors
27. final inspection.
28 remove isolation.
regards....
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