Category Archives for Inspection & Maintenance

Hydrostatic Tests on Furnaces

A hydrostatic test should be applied to all furnace heating elements after replacement of tubes or headers and usually after routine tube cleaning operations. During the test, all personnel should be out of the furnace except the inspectors. The inspector … Continue reading

18. May 2018 by sam
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Inspection of Furnace Setting and Appurtenances

Note the condition of the weather roof steelwork and sheeting. Check the roof for proper drainage. Inspect the furnace steelwork for corrosion and distortion. Check the ties at the top and bottom of the buckstays. Check the side coil support … Continue reading

18. May 2018 by sam
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Inspection of Stacks

Visually inspect the outside surface of welded steel stacks with telescope or binoculars from the ground to determine the general stack condition. Look for evidence of overheating and heavy scaling, rusting of the external surfaces or cracks. Steel stacks may … Continue reading

18. May 2018 by sam
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External Inspection of Furnace Fireboxes

Inspect the arch or roof tile and the tile hangers and supports. The hangers usually fail under the insulation covering the arch. Check for faulty soft insulation covering the arch. Large cracks or missing insulation allows gases to escape to … Continue reading

18. May 2018 by sam
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Internal Inspection of Furnace Fireboxes

Inspect the floor, end walls, burner walls, and bridge walls for excessive bulging, cracking or general deterioration. Bulged areas in the end walls, side walls, or burner walls usually indicate that the brick anchors are broken; therefore, the walls are … Continue reading

18. May 2018 by sam
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External Inspection of Boiler Fireboxes

Inspect the casting for holes from escaping gases. If holes are evident, the insulation between the tile wall and the casing are deteriorated. Investigate the cause of the leakage and make the necessary repairs. Casing should also be checked for … Continue reading

18. May 2018 by sam
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Internal Inspection of Boiler Fireboxes

Note the depth of the slag buildup on the floor. When it reaches the bottom of the access doors, the floor is usually replaced. Inspect the shaped face blocks on the hanging walls for spalling or general deterioration. If the … Continue reading

18. May 2018 by sam
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Inspection of Tube-End Support Casting and Hanger Supports

The tube-end supports are usually of cast material, ribbed for strength, and insulated on the fire side. They support the tube ends and the headers and protect the headers from direct contact with the high furnace temperatures. Close inspection of … Continue reading

18. May 2018 by sam
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Inspection of Plugs, Holding Members, and Screws

Inspect all plugs for corrosion or mechanical damage on the seating surface. Make sure that the plug has adequate bearing surface in the header seat (i.e., that it does not sit too high or too low in the seat). The … Continue reading

18. May 2018 by sam
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Inspection of Crossovers and Risers

Inspect the outside surface of crossovers and riser pipes or tubing for cracks at welds or rolled sections. Check rolled sections, flange, pressure and thermowell connections for leakage. Hammer-test or ultrasonically gage all crossovers and risers. Inspect the inside surfaces … Continue reading

18. May 2018 by sam
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