Boiler Inspection, Repair and Testing

Inspection, repair and testing of two 18 tonne / hour steam generating boilers.

The Project

We were approached by our client to manage the inspection, repair and pressure test of their two boiler units. The boilers had been operational for one year, but process conditions lead to extensive wear and degradation due to thermal cycling. As this was the first inspection to be conducted since commissioning, the client’s insurers took great interest in the delivery and results of this project.

Scope of Engineering Works Our Approach The Results

We were asked to take responsibility for the inspection, repair and hydrostatic pressure testing of the boilers. The scope included the economiser, smoke tube boiler, evaporator & superheater units and the steam drum.

We initially inspected the boilers, recording any damage to refractory and locations where leaks were present. Excessive wear was noted around the second stage superheater where the refractory was critically damaged, with multiple leaks being identified. We also identified cracks in the smoke tube boiler internal holding plate, caused by excessive pressure fluctuations within the system.

We engaged a suitable boiler repair company and ensured that all repairs were made safely and in the designated time frame.

Once the repairs were completed, we prepared the entire boiler system for pressure test at 38 Bar. The pressure being held for one hour as specified by the client’s insurers, who approved the units for restart.

We ensured that the project was completed safely in the designated timeframe. We developed a close working relationship with the boiler repair company and our client’s insurers, leading all communication with transparency and openness.

Our client was impressed by our ability to deliver the project on time, despite the extensive damage being identified within the newly operational boilers.

The project was delivered to program and ensured the client could safely operate the plant without further delay.

Our client was concerned regarding the level of damage that was found within both boiler units after the short operational period and we provided advice and recommendations on how to modify their process to reduce wear during the following operational period.