Oleh:

PURNAWAN SAPTA WARDHANACertified CSWIP3.1 #81201

9 Agustus 2014

BOILER LIFE ASSESSMENT

SUHU YANG SANGAT TINGGI PADA BOILER (KETEL UAP) LEBIH DARI 15000F ATAU 8000C

DAPAT MENYEBABKAN TERBENTUKNYA BRITTLE IRON OXSIDE ATAU DISEBUT

MAGNETIT DIDALAM DAN DILUAR PERMUKAAN DRUM PLATE.

PADA SUHU YANG TINGGI, UAP AIR AKAN BEREAKSI DENGAN BESI BAJA UNTUK

MEMBENTUK MAGNETIT DAN HYDROGEN.

KECEPATAN REAKSI INI MENINGKAT SEIRINGAN DENGAN SUHU YANG MENINGKATSEHINGGA MENYEBABKAN ATOM OKSIGEN AKAN BERDIFUSI KE DALAM MELALUILAPISAN MAGNETIT , DAN ATOM BESI AKAN MENYEBAR KE LUAR , SEHINGGASCALE/KERAK TERUS TUMBUH BAHKAN SETELAH PERMUKAAN TABUNG BENAR-BENARTERTUTUP OLEH SCALE. DINDING TABUNG YANG TERTUTUP SCALE AKAN PANASHINGGA SUHU DI LUAR JANGKAUAN OPERASI YANG DIINGINKAN. AKIBAT KONTAKJANGKA PANJANG DENGAN SUHU YANG TERLALU TINGGI DAN DIKOMBINASIKANDENGAN TEKANAN YANG SANGAT TINGGI DI DALAM TABUNG, AKAN MENYEBABKANINTERGRANULAR MIKRO ATAU RETAK PADA LOGAM DAN CREEP DEFORMASI (PEMBENGKAKAN LAMBAT ATAU MENGGEMBUNG LOGAM ) DIMANA MELEBIHI YIELDSTRENGTH MATERIAL, YANG PADA AKHIRNYA MENYEBABKAN KEGAGALAN TABUNGDENGAN MENYEBABKAN MELEDAK .

MASALAH SEKUNDER ADALAH, DI MANA POTONGAN OKSIDA SCALE BREAK ( BIASANYAKARENA TEGANGAN TEROKSIDA OXFOLIATIONMAL SELAMA BOILER STARTUP ATAUSHUTDOWN) YANG MASUK KE TURBIN DAN MENYEBABKAN KOROSI PADA TURBIN

UNTUK ITU BOILER HARUS DILAKUKAN INSPECTION

KENAPA BOILER HARUS DI INSPECTION SECARA

BERKALA??????????

DAFTAR ISI

1. TUJUAN BOILER LIFE ASSESSMENT

2. EVALUASI SELAMA OPERASI DENGAN INSPECTION

3. PERSIAPAN UNTUK INSPECTION

4. DATA REQUIREMENT

5. INSPECTION PADA HIGH PRESSURE PARTS.

6. SAMPLE TUBE INSPECTION *)

7. VISUAL INSPECTION PADA PART-PART BOILER .

8. SURVEY KUALITAS AIR

9. VISUAL INSPECTION UNTUK AUX EQUIPMENT

10. HIGH PRESSURE PARTS INSPECTION DETAILS

1. Mengevaluasi keadaan sekarang dan kondisi komponen boiler dalam rangka Untuk

melanjutkan operasi boiler stabil dan handal

2. Evaluasi sisa umur untuk Superheater dan alat pemanas dengan pemeriksaan UT

scale thickness

3. Evaluasi creep dan skema inspeksi masa depan dengan pemeriksaan metalurgi

untuk water wall, economizer, Superheater dan Reheater tube

4. Evaluasi tingkat kerusakan creep Superheater dan reheater dengan uji kekerasan

(Hardness Test)

5. Evaluasi sisa umur berdasarkan Pengukuran ketebalan untuk water wall,

6. Evaluasi sisa umur berdasarkan penipisan ketebalan untuk economizer karena

Korosi Suhu rendah,

7. Evaluasi sisa umur berdasarkan penipisan ketebalan untuk Superheater dan

reheater tube karena Korosi Suhu tinggi

8. Konfirmasi penyebab inner scale generation

9. Evaluasi sisa umur berdasarkan cek struktur logam ,inner scale , dll untuk tabung

sample (Destructive test)

1- TUJUAN DARI BOILER LIFE ASSESSMENT

2. EVALUASI SELAMA OPERASI DENGANINSPECTION

FAILURE PENYEBAB KEGAGALAN

FENOMENA LIFE EVALUATION INSPECTION ITEM

CREEP Penyumbatanoleh material asing

Penambahan danpertumbuhan dariscale pada inner surface

Long-term stress

Swelling (Deformasimengelembung)

Perubahanstruktur Metal

Outside diameter danpengukuran thickness

Metallurgical inspection *)

Metallurgical inspection for SH, RH header, *)

Metallurgical inspection *) dan NDT (UT) untuk main steam pipe line danhigh temperature RH pipe

FATIGUE (Kelelahan)

siklus thermal stress

Pertumbuhancrack

Stress analysis

Surface crack inspection (PT,MT)

NDE (PT) pada area welding untukSuperHeater dan ReHeater Tube

CORROSION FATIGUE

siklus thermal stress disebabkankorosi lingkungan

interaksicorrosion danfatigue

Ultrasonic test

Sample tube inspection *)

Sample tube inspection pada SH, RH dan water wall *)

Check Burner Nozzle dan Wind Box Damper

CORROSION

EROSION

High temp corrosion

Low temp corrosion

Ash erosion

Penipisanketebalan

Pengukuran thickness tahunan

Pengukuran tube thickness pada SH ,RH, Water Wall and Eco dengan UT

Steam drum

Boiler aux

Eco Hanger tube dengan borescope, etc

3-PERSIAPAN UNTUK INSPECTION BEFORE INSPECTION

PEMBERSIHAN SUPERHEATER, REHEATER, ECONOMIZER DAN WATER WALL

AIR HEATER WASHING

SCAFFOLDING

REMOVAL OF INSULATION

OPEN MAN HOLES, INSPECTION HOLES, FLANGES DLL

DURING INSPECTION SURFACE PREPARATION OF INSPECTION PARTS

SURFACE FINISHING (GRINDING) OF INSPECTION PARTS

PERALATAN INSPECTION

CUTTING TUBES *)

WELDING TUBES *)

MATERIAL REQUIREMENT NEW TUBES *)

MAN HOLE PACKING

INSULATION

PERIOD OF INSPECTION

ONE WEEKS

4- DATA REQUIREMENT

BOILER REFERENCE DATA STEAM TEMPERATURE 0C

MAXIMUM STEAM FLOW TON/HR BOILER DESIGN PRESSURE KGM/CM2

FEED WATER TEMP 0C

REHEATED INLET STEAM TEMPERATURE 0C REHEATED OUTLET STEAM TEMPERATURE 0C

REHEATER DESIGN PRESSURE KGM/CM2

KIND OF FUEL (BAHAN BAKAR) GAS, OIL, SAWIT

FUNCTIONAL INSPECTION WITH BOILER IN OPERATION MENGUMPULKAN DRAWINGS DAN TECHNICAL DATA

RECORDING DARI ACTUAL OPERASI DAN DATA PERBEDAANLOADS DAN KONDISI PADA LOG SHEET BOILER DAN VERIFIKASIDARI DATA BOILER SAAT OPERASI

MENGUMPULKAN DATA THERMAL HISTORY PADA SAAT OPERASI

PERALATAN YANG DIPUNYA INDOMARINE

1. UT THICKNESS

2. PORTABLE HARDNESS TEST

3. BORESCOPE

4. LAPTOP UNTUK PENGOPERASIAN BORESCOPE

5. UT SCALE THICKNESS ATAU BISA MENGGUNAKAN UT PHASED ARRAY

6. PORTABLE SCANER (JIKA BUKAN BOILER IM UNTUK SCAN DRAWING)

PERALATAN YANG DIBUTUHKAN

5-INSPECTION PADA HIGH PRESSURE PARTS

NON DESTRUCTIVE TEST MENGIKUTI ITEM SEBAGAIBERIKUT:

1. ECONOMIZER HEADERS, COILS, PIPING FROM ECONOMIZER TO STEAM DRUM,.2. STEAM DRUM.3. FURNACE WATER WALLS, (SCREEN TUBE/REAR WALL SISI LUAR ATAS, ROOF WALL,

FRONT WALL, SIDE WALL L & R, BANK TUBE, UPPER CONNECTION PIPE/RISER ,WATER WALLS HEADERS.

4. SATURATION STEAM PIPE.5. PRIMARY, SECONDARY SUPER HEATER (IF ANY)6. CONNECTING PIPE BETWEEN PRIMARY SUPERHEATER AND SECONDARY

SUPERHEATER. (IF ANY)7. REHEATER / AIR PREHEATER.8. MAIN SUPERHEATER STEAM PIPES

**INSPECTION 7 ITEM

1. EXTERNAL VISUAL INSPECTION2. INTERNAL VISUAL INSPECTION WITH BORESCOPE3. UT FOR THICKNESS MEASUREMENTS BY UT 4. PT AND UT ON CIRCUMFERENTIAL WELDS (R)5. PT ON PIPING ATTACHMENTS (R)6. PT ON NOZZLES WELDS OF THE COIL TUBES (R)7. PT ON NOZZLES WELDS TO THE SHELL OF THE

INLET/OUTLET PIPE

THE MINIMUM REQUIRED THICKNESS

t = minimum required thickness.

D = outside diameter of cylinder.

e = thickness factor for expanded tube ends.

P = maximum allowable working pressure.

S = maximum allowable stress value at the design temperature of the metal.

DESIGN / OPERATING INFORMATIONUNTUK PERHITUNGAN WAKTU YANG TERSISA BERDASARKAN THICKNESS

DESIGN INFORMATION MATERIAL TYPE / GRADE NOMINAL OUTSIDE DIAMETER DESIGN PRESSURE DESIGN THICKNESS DESIGN TEMPERATURE ORIGINAL NOMINAL

THICKNESS LAMA BOILER BEROPERASI

OPERATING INFORMATION MAXIMUM DESIGN METAL

TEMPERATURE TUBE NORMAL OPERATING

PRESSURE ORIGINAL MEASURED

MINIMUM THICKNESS RATA-RATA THICKNESS

METAL

Thickness

measurements

of water wall

tubes furnace

PERHITUNGAN BOILER LIFE ASSESSMENT

MENCARI LAJU KOROSI

= ( )

PENENTUAN BOILER LIFE ASSESSMENT

=( )MIN

DENGAN SYARAT KUALITAS AIR, CARA MENGOPERASIKAN

BOILER SAMA SELAMA BEROPERASI SELAMA INI.

6-SAMPLE TUBE - *)

DESTRUCTIVE TEST PADA SAMPLE TUBE DI AREA WATER WALL ,SUPERHEATER DAN REHEATER TUBES

DIAGNOSA SELAMA OPERASI BERDASARKAN CHECK STRUCTURE METAL, THICKNESS, INNER SCALE, DLL *)

SAMPLE TUBE YANG DIAMBIL SESUAI DENGAN HASIL PENGUKURAN HARDNESS TEST

INVESTIGATION ITEMS VISUAL INSPECTION NON DESTRUCTIVE TEST CHEMICAL ANALYSIS *) MEASUREMENT OF THE TUBE DIMENSION HARDNESS MEASUREMENT

CROSS SECTIONAL MICROSTRUCTURE OBSERVATION *) STEAM OXIDATION OBSERVATION CREEP RUPTURE TEST *) PENGUKURAN THICKNESS PADA INNER SCALE

INFORMATION MATERIAL SAMPLE TUBE TUBE DIMENSION

SAMPLE TUBES UNTUK MICRO TEST

THINNING OF BULGED ZONE INTERNAL SURFACE SCALE EXTERNAL SURFACE SCALE

7-VISUAL INSPECTION UNTUK PART-PART DARI BOILER

BURNER

WIND BOX

HANGER FOR RISER PIPE

OUTER CASING

BUCKSTAY

8- SURVEY KUALITAS AIR

INSPECTION INI UNTUK MENGKONFIRMASI

PENYEBAB DARI SCALE/KERAK

INSPECTION ITEMS

CHECK OF LABORATORY ANALYSIS METHOD FOR

QUALITY ITEMS

KONFIRMASI HASIL KUALITAS AIR SEBELUM

DIOPERASIKAN

CHECK INSTRUMENT CONDITION ON SAMPLING RACK

USED FOR WATER QUALITY CONTROL

CONFIRMATION OF PH VALUE AND IRON/COPPER

BALANCE IN THE CYCLE

9-VISUAL INSPECTION PADA AUX EQUIPMENT

INSPECTION INI UNTUK MENGETAHUI PENYEBAB SCALE

GENERATION

CONDENSER HOT WELL. CONDENSER TUBE SIDE DEAERATOR. LOW PRESSURE-FEED

WATER HEATER. FEED WATER TANK. HIGH PRESSURE-FEED

WATER HEATER.

10-HIGH PRESSURE PARTS INSPECTION DETAILS

1. ECONOMIZER HEADERS ,COILS, PIPING FROM ECONOMIZER TO

STEAM DRUM ,

2. STEAM DRUM

3. FURNACE WATER WALLS, (SCREEN TUBE/REAR WALL, ROOF WALL

SISI LUAR ATAS, FRONT WALL, SIDE WALL L & R, BANK TUBE, UPPER

CONNECTION PIPE/RISER ,WATER WALLS HEADERS)

4. SATURATION STEAM PIPE

5. PRIMARY, SECONDARY SUPERHEATER

6. CONNECTING PIPE ANTARA PRIMARY SUPER HEATER DAN

SECONDARY SUPERHEATER

7. REHEATER/ AIR PREHEATER

8. MAIN SUPERHEATER STEAM PIPES

10-1 ECONOMIZER

NDE FOR HEADERS EXTERNAL VISUAL INSPECTION INTERNAL VISUAL INSPECTION WITH BORESCOPE MEASUREMENT OF THICKNESS BY UT PT ON NOZZLES WELDS OF THE COIL TUBES AND HEADERS

ATTACHMENTS PT AND UT ON CIRCUMFERENTIAL WELDS BETWEEN HEADER AND

CONICAL PIECES

NDE FOR TUBE EXTERNAL VISUAL INSPECTION MEASUREMENT OF ECONOMIZER TUBE AND HANGER TUBE THICKNESS

WITH BORESCOPE UT FOR THICKNESS MEASUREMENTS

NDE FOR PIPING FROM ECONOMIZER TO STEAM DRUM EXTERNAL VISUAL INSPECTION FOR PIPING, HANGERS AND SUPPORTS UT FOR THICKNESS MEASUREMENTS PT AND UT ON CIRCUMFERENTIAL WELDS (RANDOM) PT ON PIPING ATTACHMENTS PT ON THE ELBOWS

10-2 STEAM DRUM

BEFORE THE NDT INSPECTIONS, THE INTERNAL PARTS OF THE DRUM SHALL BE DISMANTLED

NDE FOR STEAM DRUM EXTERNAL VISUAL INSPECTION INTERNAL VISUAL INSPECTION UT FOR SHELL THICKNESS MEASUREMENTS UT FOR HEAD THICKNESS MEASUREMENTS PT AND UT ON CIRCUMFERENTIAL AND LONGITUDINAL

WELDS (R) PT ON STEAM DRUM ATTACHMENTS (SADDLES AND

ACCESSORIES) PT ON NOZZLES WELDS

NDE FOR DOWNCOMERS & FEEDERS (FEED WATER PIPE)

EXTERNAL VISUAL INSPECTION FOR PIPING, HANGERS AND SUPPORTS

UT FOR THICKNESS MEASUREMENTS PT AND UT ON CIRCUMFERENTIAL WELDS PT ON PIPING ATTACHMENTS

10-3 FURNACE WATER WALLS, (SCREEN TUBE/REAR WALL, ROOF WALL SISI LUAR ATAS, FRONT WALL, SIDE WALL L & R, BANK TUBE, UPPER CONNECTION PIPE/RISER ,WATER WALLS

HEADERS

NDE FOR FURNACE WATER WALLS, SCREEN, ROOF WALL EXTERNAL VISUAL INSPECTION

UT FOR THICKNESS MEASUREMENTS METALLOGRAPHIC EXAMINATION BY PLASTIC REPLICAS *)

SAMPLES FOR DESTRUCTIVE TEST *)

NDE FOR RISER EXTERNAL VISUAL INSPECTION

UT FOR THICKNESS MEASUREMENTS

NDE FOR HEADERS EXTERNAL VISUAL INSPECTION

INTERNAL VISUAL INSPECTION WITH BORESCOPE

UT UNTUK THICKNESS MEASUREMENTS PT PADA NOZZLES WELDS DARI COIL TUBES

PT PADA CABANG (T) WELDS DAN HEADERS ATTACHMENTS, TERMASUK DRAINS TUBES

10-4 SATURATION STEAM PIPE

NDE FOR EACH PIPE

EXTERNAL VISUAL INSPECTION

UT FOR THICKNESS MEASUREMENTS

PT AND UT ON CIRCUMFERENTIAL WELDS (R)

PT ON PIPING ATTACHMENTS

PT ON THE ELBOWS EXTRADOS

10-5 PRIMARY,SECONDARY SUPERHEATER

NDE FOR THE HEADERS (TYPE PENDAND : 1 PCS ; TYPE U ON TOP : 2PCS) EXTERNAL VISUAL INSPECTION INTERNAL VISUAL INSPECTION WITH BORESCOPE UT FOR THICKNESS MEASUREMENTS UT FOR HEADER THICKNESS MEASUREMENTS PT ON NOZZLES WELDS OF THE COIL TUBES (R) PT ON NOZZLES WELDS TO THE SHELL OF THE INLET/OUTLET

PIPE PT AND UT ON CIRCUMFERENTIAL WELDS BETWEEN HEADER

AND HEADS/ PIPING PT ON HEADERS ATTACHMENTS METALLOGRAPHIC EXAMINATION BY PLASTIC REPLICAS *)

NDE FOR COILS EXTERNAL VISUAL INSPECTION UT FOR THICKNESS MEASUREMENTS INTERNAL VISUAL INSPECTION WITH BORESCOPE HARDNESS MEASUREMENTS SAMPLES FOR DESTRUCTIVE EXAMINATIONS *)

10-6 CONNECTING PIPE ANTARA PRIMARY DAN SECONDARY SUPERHEATER,

DESUPERHEATER NDE FOR CONNECTING PIPE

EXTERNAL VISUAL INSPECTION UT FOR THICKNESS MEASUREMENTS PT AND UT ON CIRCUMFERENTIAL WELDS (R) PT ON PIPING ATTACHMENTS PT ON THE ELBOWS EXTRADOS METALLOGRAPHIC EXAMINATION BY PLASTIC REPLICAS

*)

NDE FOR DESUPERHEATER EXTERNAL VISUAL INSPECTION INTERNAL VISUAL INSPECTION WITH BORESCOPE UT FOR THICKNESS MEASUREMENTS PT ON CIRCUMFERENTIAL WELDS (R) METALLOGRAPHIC EXAMINATION BY PLASTIC REPLICAS

*)

10-7 REHEATER / AIR PREHEATER

NDE FOR EACH ONE OF THE HEADERS

EXTERNAL VISUAL INSPECTION INTERNAL VISUAL INSPECTION WITH BORESCOPE UT FOR THICKNESS MEASUREMENTS PT ON NOZZLES WELDS OF TUBES PT ON NOZZLES WELDS TO THE SHELL OF THE

INLET/OUTLET PIPE PT AND UT ON CIRCUMFERENTIAL WELDS (R) PT ON HEADERS ATTACHMENTS (R) METALLOGRAPHIC EXAMINATION BY PLASTIC REPLICAS *)

NDE FOR COILS

EXTERNAL VISUAL INSPECTION UT FOR THICKNESS MEASUREMENTS INTERNAL VISUAL INSPECTION WITH BORESCOPE HARDNESS MEASUREMENTS SAMPLES FOR DESTRUCTIVE EXAMINATIONS *)

10-8 MAIN SUPERHEATER STEAM PIPES

NDE FOR EACH PIPE

EXTERNAL VISUAL INSPECTION

UT FOR THICKNESS MEASUREMENTS

PT AND UT ON CIRCUMFERENTIAL WELDS (R)

PT ON PIPING ATTACHMENTS (R)

PT ON THE ELBOWS EXTRADOS

PT ON NOZZLES WELDS TO THE PIPE

METALLOGRAPHIC EXAMINATION BY PLASTIC REPLICAS *)