Mechanical Integrity Activities for Heaters/Furnaces/Boilers

Peer Review Copy

 Attribute Design, Fabrication, and Installation Inspection and Testing Preventive Maintenance Repair
Example Activity Frequency Activity Frequency Activity Frequency Activity Frequency
Activities and Heat or steam rate duty/fluid As-required for Inspection of Scheduled by user, Activities As-required to Tube replacement As required by the condition of the
Typical service requirements fabrication and heater or usually in identified from meet preventive Burner replacement or equipment, based on
Frequencies  Pressure rating installation furnace conjunction with RCM or similar maintenance repair recommendations from inspection
 Materials selection firebox and planned unit work planning schedule and boiler and testing or preventive
tubes shutdown or when an initiatives, such as: operating permit Insulation/refractory repair maintenance activities
Fabrication contractor imminent failure requirements Tube or piping support,
qualification  Process
condition is visible conditions hanger and anchoring
 Design approval by monitoring/ systems repair or renewal
owner tracking Commissioning activities
 Welding/QC plan  Metal following repair
approval temperature
monitoring
Fabrication/storage/ shipping Inspection of Inspection schedule  Water
Installation boilers, steam is not code derived, quality testing
Acceptance inspection and drums, tubes, but is generally  Efficienc
testing and firebox mandated by y performance
Documentation preparation jurisdictional monitoring
Acceptance and turnover Waste heat requirements
Commissioning boiler
inspection

Hazardous
waste
incinerator
inspection
QA practices for equipment fabrication and installation Jurisdictional requirements for boilers, Company or jurisdictional requirements Performed when indicated by failure, or based on recommendations
Technical Basis
and reliability issues for heaters and from PM or inspection and testing activities
for Activity and
furnaces
Frequency
ASME Boiler and Pressure Vessel Code and NBIC Acceptance criteria from NBIC or Upper and lower safe limits for process ASME Boiler and Pressure Vessel Code and NBIC
Acceptance
jurisdictional requirements. conditions defined in the process safety
Criteria
Company engineering standards, or facility-specific standards Company standards for evaluating tube information, such as pressure, temperature, Company engineering standards, or facility-specific standards for
for heaters and furnaces life and refractory damage fluid composition, and velocity. heaters and furnaces
Typical Failures Incorrect material or weld metal, incorrect pressure rating for Tube ruptures, tube bulging and Process conditions, such as outlet Incorrect material or weld metal, incorrect pressure rating for a
of Interest a component, leak during testing, weld defects outside of distortions, creep damage, steam leaks, temperatures, stack temperatures, component, leak during testing, weld defects outside of acceptance
acceptance criteria, high hardness readings, use of unqualified process fluid leaks, refractory failure, combustion efficiency, heat input, flow criteria, high hardness readings, use of unqualified welder or
welder or welding procedures, dimensional errors, incorrect structural support failure balances, and tubular meal temperatures, welding procedures, dimensional errors, incorrect refractory
refractory material, incorrect refractory installation or cure, exceed safe operating limit material, incorrect refractory installation or cure, incorrect spring
incorrect spring hanger setting, damage to finned tube hanger setting, damage to finned tube

Peer Review Copy

 Attribute Design, Fabrication, and Installation Inspection and Testing Preventive Maintenance Repair
Personnel Boilers: ASME and National Board fabrication requirements National Board inspection certifications Company requirements for tasks Boilers: ASME and National Board fabrication requirements
Heaters and Ffurnaces: Company requirements, and for boilers per jurisdictional Heaters and Ffurnaces: Company requirements, and documented
Qualifications
documented craft skills for installation, NDE qualifications, requirements craft skills for repairs, NDE qualifications, and ASME Section IX
and ASME Section IX welding requirements for welders Optional industry certifications (API- welding requirements for welders, optional industry certifications
570, 510) or company-specific training (API-570, 510), or company-specific training for inspection of
for heater and furnace inspection firebox piping
Written procedures describing: Written procedures describing the Written procedures describing the PM Craft skill procedures for typical tasks encountered in repairs
Procedure
 Engineering standards for specification of equipment inspection or test activity including: activity including: (e.g., welding, gasket installation bolt tightening)
Requirements
 Project management (including hazard and design review  The manner, the extent, the  The manner, the extent, the location, Job-specific procedures for unique or complex repairs, or for
schedules) location, and the date the inspection and the date the inspection or test is jobs with specialized technical content (e.g., coil or tube
 Vendor qualification or test is performed and by whom performed and by whom replacement, new spring hanger settings, refractory repairs or
 The documentation and analysis of  The documentation and analysis of burner adjustments)
 Documentation requirements
results results Job-specific procedures with process engineering input for
 Project acceptance and turnover requirements chemical cleaning
 The resolution of functions or  The resolution of functions or
condition not meeting acceptance condition not meeting acceptance
criteria criteria
Company documentation requirements typically include: Results and analysis of each inspection Results are usually recorded by exception Repair history is maintained with the equipment inspection history
Documentation
Manufacturers’ data forms (boilers), welding qualifications, are documented for the life of the in the equipment history file files
Requirements
weld map, design calculations, material certifications, QC equipment
results, as-built drawings, and pressure test reports

Peer Review Copy

Peer Review Copy