Boiler Inspection Guide

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
BOILER INSPECTION, PRESSURE TEST

and CHEMICAL CLEANING
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Mechanical
File Reference: MEX-104.05
For additional information on this subject, contact

PEDD Coordinator on 874-6556
Introduction to Boilers
Boiler Inspection, Pressure Test and Chemical Cleaning
Section
Page
INFORMATION ............................................................................................................... 3
STANDARDS .................................................................................................................. 3
Saudi Aramco Engineering Standards (SAES)..................................................... 3
Other Saudi Aramco Standards............................................................................ 3
Industry Standards ............................................................................................... 3
PREPARATION FOR INSPECTION ............................................................................... 4
EXTERNAL BOILER INSPECTION ................................................................................ 6
Ladders, Stairways and Platforms ........................................................................ 7
Air Ducts and Flue Gas Ducts .............................................................................. 8
Support Structure and Boiler Casing .................................................................... 8
Stack .................................................................................................................... 9
Boiler Piping ....................................................................................................... 10
Instrumentation................................................................................................... 10
Paint and Insulation ............................................................................................ 10
INTERNAL BOILER INSPECTION................................................................................ 11
Safe Entry........................................................................................................... 11
Fans ................................................................................................................... 12
Firebox Refractory and Insulation....................................................................... 12
Burners ............................................................................................................... 13
Convection Section............................................................................................. 13
Tube External ..................................................................................................... 14
Boiler Steam/Mud Drum ..................................................................................... 17
Inspection Tools ................................................................................................. 18
Tube Internal ...................................................................................................... 18
HYDROSTATIC PRESSURE TEST.............................................................................. 19
Purpose .............................................................................................................. 19
Preparation ......................................................................................................... 20
Testing................................................................................................................ 21
CORROSION RATES ................................................................................................... 22
Example Problem 1 ............................................................................................ 23
Remaining Life.................................................................................................... 23
Example Problem 2 ............................................................................................ 24
PZV SAFETY RELIEF VALVES .................................................................................... 25
Bench Test ......................................................................................................... 25

Pressure Test ..................................................................................................... 26
BOILER CHEMICAL CLEANING .................................................................................. 27
Requirement and Recommendations ................................................................. 28
Steps .................................................................................................................. 28
Preparation .............................................................................................. 29
Alkaline Boil Out ...................................................................................... 29
Acid Cleaning........................................................................................... 29
Neutralizing and Passivation.................................................................... 29
WORK AIDS.................................................................................................................. 30
WORK AID 1: RESOURCES USED TO CALCULATE CORROSION RATE
AND REMAINING LIFE .......................................................................... 30
GLOSSARY .................................................................................................................. 31
ADDENDUM ................................................................................................................. 32
ADDENDUM A: BOILER LAY-UP PROCEDURES ...................................................... 33
ADDENDUM B: ABQAIQ CHEMICAL CLEANING PROCEDURE ............................... 35
ADDENDUM C: STANDARDS FOR BOILER INSPECTION........................................ 49
ADDENDUM D: HOW TO MAKE A BOILER FIRESIDE INSPECTIONS ..................... 55
REFERENCES.............................................................................................................. 57
List of Figures
Figure 1. Caustic Corrosion.......................................................................................... 14
Figure 2. Internal Chemical Deposits ........................................................................... 15
Figure 3. Boiler Steam Drum Inspection....................................................................... 17
ii
INFORMATION
STANDARDS
The following standards define the conditions that must be met
by inspections, pressure testing and chemical cleaning of
boilers.
Saudi Aramco Engineering Standards (SAES)

SAES-A-004
General Requirements for Pressure Testing
SAES-A-005
Safety Instruction Sheets
SAES-A-007
Hydraulic Testing Fluids and Testing

Procedures
SAES-J-600
Pressure Relieving Devices
Other Saudi Aramco Standards

32-SAMSS-021 Manufacture of Industrial Watertube Boilers
GI 2.102
Pressure Testing Safety
GI 447.002
Pressure Relief Valves
GI 447.003
Safety Relief Valve Test, Inspection and

Quality Assurance
GI 402.001
General Instruction on Chemical Cleaning
SAEP-1025
Chemical Cleaning of Boilers
SAEP-1026
Mothballing/Lay-up Procedures for Boilers
Industry Standards
ASME Section 1
Boiler and Pressure Vessel Code
ASME Section VII
Guidelines for the Care of Power Boilers
NBIC
National Board Inspection Code
API RP 572
Inspection of Pressure Vessels
API RP 573
Inspection of Fired Boilers and Heaters
API RP 574
Inspection of Piping, Tubing, Valves
API RP 576
Inspection of Pressure Relieving Devices
PREPARATION FOR INSPECTION

Inspections are done to determine the amount of maintenance
required to have the equipment operate properly, until the next
turnaround. Boilers should be inspected at least every two
years. Inspection intervals are based on service and
experience.
Inspection is not an exact science and requires the use of
judgment and experience as well as science.
Records should be reviewed before an inspection, to become
thoroughly familiar with the equipment. This review should result
in identifying expected problems and planning areas of
emphasis for the planned inspection. The following records that
should be checked are as follows:
Original Design Drawings
Piping and Instrumentation Diagrams (P&IDs)
Boiler Log
Maintenance Records
Safety Instruction Sheets (SIS)
Hydrostatic Test Diagram
Previous hydrostatic test results
The original design drawings and the P&IDs provide information

on the pressure and temperature of the original design. The
original design drawings indicate inspection points, with notes
on inspection procedures. These drawings also contain notes on
how to access equipment. The P&IDs should also show all pipe
sizes, materials of construction, vent and drain locations, and
blind. They also provide material specifications and original
thickness of equipment.
The boiler log provides a record of each inspection,

maintenance check, and notes on the equipment. These notes
are necessary to prepare for inspection. The maintenance
records indicate conditions found in a previous inspection that
required maintenance. The Safety Instruction Sheets (SIS)
provides operating pressure and temperature information, and
pressure test targets. It also contains the retirement thickness
on critical piping. The hydraulic test diagram is a line drawing
showing blinds, piping layout, and location of pressure test
connections. The test diagram will specify the relief valve size,
set pressure, and location. Previous hydraulic test results
indicate problem areas from previous inspections.
EXTERNAL BOILER INSPECTION

The external boiler inspection may be conducted when the
boiler is operating or shutdown. If possible, an external
inspection should begin before shutdown in order to detect hot
spots, leaks, etc. during operation. An external inspection
determines the amount of deterioration and is used to evaluate
whether the boiler is operating safely.
The external boiler inspection may be conducted at any time
and should include the following:
Ladders, stairways and platforms
Air and flue gas ducts
Boiler support structure
Stack
Support structure & boiler casing
Boiler piping
Instrumentation
Safety relief valves
Paint and insulation
Boiler circulating pumps
Vents and drains
Ladders, Stairways and Platforms

This inspection will insure that you can move around the
equipment. The primary means of inspection is visual.
Hammering and scraping to remove oxide scales and other
corrosion products may also be necessary.
Inspect for the following:
Cracks - Inspect welds and structural steel for cracks.

Remove floor plates to inspect supporting structure. Inspect
crevices by picking them with a pointed scraper. Determine if
a crack warrants repair or further inspection via ultrasonic
measurements.
Tightness of bolts - Bolt tightness can be determined by

tapping with an inspectors hammer or by trying the nuts with
a wrench. Note any loose bolts on the inspection sheet. Note
any thread wear. Bolts that continue to loosen up between
inspections may indicate a structural fault.
Condition of paint or galvanized material
Wear on ladder rungs and stair treads. Inspect depressions

carefully because water lying in depressions can cause
corrosion. Find loose or broken parts by tapping with an
inspectors hammer.
Security of handrails - Inspect for broken braces, supports,

or signs of movement. Inspect anchor points for
deterioration.
The condition of flooring - Check for any unsafe conditions.

Check for worn flooring that could become slippery. Be
especially observant of any overhangs in and around
platforms and ladders that may project into path during use.
Air Ducts and Flue Gas Ducts

Inspect ducts for any signs of oxidation and the condition of the
painted surfaces while the unit is in operation. Some breeching
and ducts are protected internally by refractory. Discoloration or
destruction of painted surfaces may indicate leakage through
the refractory. Inspect the seams and joints for any indications
of cracking and leakage. Hammer testing can indicate thin areas
in ducting and breeching. Thin areas may indicate internal
corrosion. Check alignment of ducts that may indicate failure of
supports or shifting of equipment. Inspect expansion joints to
ascertain their general condition and the presence of cracks in
the thinner, flexible joint material.
Support Structure and Boiler Casing

The support structure includes all beams, columns, and girders
that support the boiler as well as foundations.
Inspect all load carrying structural steel for bending which may
indicate weakening due to overloading, lateral forces, corrosion
or overheating due to leaks in the refractory. Inspect structural
steel for corrosion. Inspect all connections between columns,
beams and girders. Visually inspect walls and wall alignment for
any signs of bulging or movement. Inspect walls for signs of hot
spots or discoloration that would indicate refractory problems.
Foundations are steel reinforced concrete. Inspect the
foundation for calcining, settling, cracks, and/or spalling. One of
the main causes of deterioration of the foundation is high
temperature. High temperature may cause calcining and/or
cracks. Calcining is the drying out of concrete so that it has very
little cohesion. Locate calcining by chipping at the suspected
area with a hammer.
Cracks in concrete may be caused by high temperature, poor
design, and/or improper installation (materials, curing). Cracks
provide an entrance for water to corrode the reinforcing steel.
When the steel corrodes, it expands making cracks wider, which
results to more corrosion. Spalling can result from internal
corrosion of reinforcing steel and/or overheating.
All foundations settle to some extent. Little or no trouble may be

experienced if the settling is small and evenly distributed. When
settlement is noted, examine all pipe connections to the boiler.
Inspect all anchor points for the support structure for indications
of excessive stress. Check various points with a bubble level to
find settlement.
Spalling is a form of concrete deterioration caused by heat,
corrosion of steel or insufficient thickness of concrete over
reinforcement.
Major cracks or spalling may indicate the necessity to removal
of a core for testing.
Note all deficiencies on the inspection sheets.
Stack
Stacks have been known to collapse when allowed to
deteriorate.
Deposits that accumulate in the stack can be explosive.
Deposits should be removed occasionally.
Inspect brick, concrete, and steel stacks for conditions that may
weaken these structures. Use field glasses to inspect high
stacks from the ground. Use infrared temperature
measurements to look for hot spots that would indicate internal
refractory problems.
Conduct a thorough hammer testing of the steel stacks. Pay
particular attention to the seams, stiffening rings, lugs, and
nozzles. Acids in the flue gas that may condense may attack the
upper cool portion of a stack.
Inspect bolts at the base and at elevated sections for loosening
and breakage. Check a loose bolt for abrasion from movement
of the structure. Inspect guy lines for corrosion. Inspect lightning
rods and grounding cables to see that they are securely
grounded and not corroded. Guy line connections to the
deadman at the bottom, and at the top are especially subject to
corrosion due to moisture settling retained around these
connections. Guy wires should be replaced at safe intervals,
since inspection is impractical between the deadman and the
top. The electrical resistance of the ground should be less than
25 ohms.
Boiler Piping
A leak or failure in a piping system may be a major problem or a
minor inconvenience, depending on the location and service.
Study historical records to determine which sections may be
approaching retirement thickness. Inspect all lines including
vents, drains, fuel supply lines, steam atomizing lines and fuel
smothering steam piping.
Inspect piping supports, and spring hangers for external
corrosion, distortion, damage, settlement or movement of the
foundation.
Inspect for internal corrosion, using ultrasonic testing. X-ray
and/or inspect internally when the lines are opened. Ultrasonic
inspection may not detect pitting, which is why internal visual
inspection is important.
Instrumentation
Inspect all lines to instrumentation for leakage. Inspect all
control valves for leakage. Verify if any safety devices or alarms
are bypassed. Alarm and shutdown settings should be verified
when possible.
Inspect water glasses, since these are extremely important in
operating the boiler. Make sure they are well lit. Have the
operator blow down the water gage in a normal manner and
observe how the level returns. A sluggish response may
indicate an obstruction in the pipe connections to the boiler.
Check pressure gages in the field against those in the control
room. Test the pressure with a test gage.
Paint and Insulation

Visually inspect the condition of the protective coating and/or
insulation. Any cracks or openings should be repaired. Any rust
spots and or bulging may indicate corrosion underneath thus,
further inspection may be required. Scrapping paint away from
blisters or rust spots often reveals pits in the vessel walls.
Measure the depth of pitting with a pit gage. The most likely
spots for paint failure are in crevices, in constantly moist areas,
and at welded seams.
10
INTERNAL BOILER INSPECTION

Internal boiler inspection can only be done when the boiler has
been shutdown, properly blanked, and purged. Internal
inspection of the boiler may require removal of much of the
casing and insulation/refractory. Boilers should not be entered
until entry can be done safely.
Internal boiler inspections are conducted whenever a boiler is
shutdown. It is opened to determine the amount of deterioration,
and evaluated if the deterioration affects the safe use of the
boiler. The main types of deterioration are as follows: corrosion,
erosion, metallurgical and physical changes, and mechanical
forces. Metallurgical changes include cracking and micro
structural changes such as graphitization, carbide precipitation,
inter-granular corrosion, and embrittlement. Mechanical forces
include thermal shock, cyclic temperature changes, vibration,
excessive pressure surges, and external loads.
Safe Entry
Entry into a boiler is not safe until the following have been done:
All fuel supply lines have been blocked in and blinded.
The boiler has been purged and tested to be free of fuel and
flue gases.
Pumps are shutdown and tagged.
All feed valves have been blocked, tagged, padlocked and

blinded, if necessary. Boiler has been drained of all liquids.
All drain lines and vents are open.
Manhole and handhole plates have been removed.
Boiler has cooled sufficiently for safe entry.
An entry permit has been issued.
11
Fans
Both forced and induced draft fans should be inspected when a
boiler is shutdown. The inspection should include:
Removal and inspection of motor including bearings and

lubricant
Rotor and rotor blade inspection for loose blades.

Examination of coupling and alignment of all parts
Inspection of induced draft fans for corrosion
Inspection of all dampers for operability and corrosion
Firebox Refractory and Insulation

The firebox refractory should be visually inspected for breakage,
crumbling, spalling, and open joints. Leakage of hot gases
through the joints when the edges have crumbled, or when the
tile or insulating concrete has fallen out, may expose supporting
steel to high metal temperatures, rapid oxidation, and corrosion.
Fly-ash corrosion may occur, when fly ash and refractory are in
contact. Fluxing occurs and produces a slag that may be fluid at
heater operating conditions. Slagging may cause rapid
deterioration of hardware, such as tube hangers. Metal oxides
found in fuel oil are the fluxing agents that cause slagging. The
metal oxide content of Saudi Aramco fuel oils is generally low
enough that fluxing and slagging is not expected.
Spalling can be caused by overheating, or heating up too fast
after a turnaround or after repairs to refractory.
Sagging of refractory would indicate problems with the
refractory supports. Overheating or corrosion of supports
usually causes support problems.
12
External deposits may indicate the need for external water

washing. The water washing procedure may include sealing the
refractory with bitumen sealer to prevent water damage of the
refractory, and the use of 0.5% soda ash solution to minimize
stress cracking of austenetic steels such as stainless steels.
Under no circumstances should raw water or salt water be used
for water washing boilers. The bitumen sealer will be burned off
during normal operation.
Inspect all baffles for condition of baffle and refractory protecting
baffles.
Inspect the linings of all stacks and ducts for cracks, wear, and
structural soundness. Use ultrasonic measurements to check
wall thickness.
Follow safety procedures when inspecting insulation that may
contain asbestos.
Burners
Inspect burners when unit is operating. Necessary adjustments
should be brought to the attention of the person responsible.
Defective burners should be repaired or replaced. Burners
should be inspected for cracks and plugging of orifices. Burner
tiles should be inspected for cracks and breakage.
Convection Section
The convection sections include the tube nests of downcomer
tubes, the superheater and the economizer.
The convection section should be inspected for the following:
a.)
Deposits on the tube surfaces that has not been removed

by soot blowers, and any damage to the extended surfaces
(fins),
b.)
Wear at the support points for the tubes, and
c.)
Any signs of overheating such as bent tubes. Glass like

deposits sometimes form on the convection tubes when
firing oil. Tube thickness should be measured where
possible.
13
Tube External
The tube thickness should be measured by ultrasonic thickness
measurements. Ultrasonic measurements give a good average
thickness but do not necessarily detect pitting.
At times, it may be necessary to take tube samples to verify the
thickness measurements and to look for internal deposits and
pitting.
An example of severe corrosion due to caustic attack is shown
in Figure 1.
Figure 1. Caustic Corrosion
A Turner gage should be used to examine for interior deposits.

The Turner gage uses changes in reluctance of a magnetic
circuit to indicate deposit thickness. The Turner gage provides a
continuous readout in scale thickness as the probe is moved
along the tubes. Readings in excess of 600 microns (0.024 in)
indicate the need for tube section removal for evaluation of
chemical cleaning. The tubes must be dry, and free from loose
sludge before the Turner gage can be used.
14
An example of severe deposits is shown in Figure 2.
Figure 2. Internal Chemical Deposits
Welds should be visually examined for cracking. Some weld xrays may be done.
Magnetic particle inspection and liquid dye penetrant
inspections are used to locate small surface cracks especially in
austenitic stainless steels.
Tubes should be examined at support points for excessive wear
and binding. Supports should be examined for corrosion,
cracking and damage, to make sure that they are operating
properly.
Tubes should be examined for overheating. This may be
indicated by bent tubes or excessive oxidation scale on the
tubes. Areas with excessive oxidation scale should be carefully
examined for corrosion. These may also be indications of
overheating of the tubes.
15
The tubes should be examined for bending or bulging that may

be caused by overheating. Bulging would be indicated by an
increase in outside diameter.
Sagging of roof tubes is generally due to overheating of
hangers. These tubes should be straightened or replaced and
the hangers replaced.
Fireside corrosion is generally caused by moisture that
accumulates in fly-ash deposits. Although fireside corrosion may
occur anywhere in the tube nest, it usually occurs where the
tubes enter the mud (lower) drum or headers.
16
Boiler Steam/Mud Drum

Figure 3 shows a steam drum being inspected.
Figure 3. Boiler Steam Drum Inspection
Boiler steam and mud drums and the tube ends are inspected
for corrosion and deposits. Ultrasonic thickness measurements
are made on the drums.
Inspect tube ends for proper projection and flaring as well as
mechanical condition.
17
Inspection Tools
Pitting may not always be detected by ultrasonic measurements
that measure the average thickness of the metal. Pit gage
measurements may be required. Some fiberscopes are
equipped to measure pits.
Cracking may require liquid dye penetrant and /or magnetic
particle to reveal the extent of cracking.
Tube Internal
Internal inspection of tubes is done to look for corrosion, pitting,
cracking and scale deposits. Tube ends can readily be
inspected while inspecting the drums.
Without taking tube samples, internal inspection of the tubes is
limited to the length (maximum of 100) of a fiberscope type of
instrument called a bore scope. A bore scope can give a view or
a TV picture of the inside of the tubes. Some fiberscopes are
equipped to measure pits. Fiberscopes are limited in that they
cannot detect build up of iron oxide inside the tubes. Even
massive deposits of hard dense iron scale can appear to be
clean metal surface.
Procedures for tube section removal and evaluation of scale
density must be carefully followed to obtain valid results.
18
HYDROSTATIC PRESSURE TEST

The following need to be defined before proceeding with this
section:
Pressure test
Any test where hydrostatic or pneumatic pressure is
applied to test equipment.
Strength test
Pressuring the vessel or piping beyond its normal
operating pressure.
Tightness test
Pressuring a vessel or piping to its operating pressure
and checking for leakage.
Test procedure - the documentation required by GI 2.102 for a

specific test. GI 2.102 provides general guidelines. SAES-A-004
provides mandatory requirements governing pressure testing.
Purpose
The purpose of a hydrostatic test is to determine if the
equipment will sustain a strength test and a tightness test.
19
Preparation
Preparation for a hydrostatic test include:
Reviewing the following:

The test procedure
The hydrostatic test diagram
The Safety Instructions Sheets (SIS). The SIS specifies
the test pressure, which is usually 1.5 times the design
pressure. This pressure will not exceed stress limits
because the equipment is much colder than design.
Examine the heater for proper isolation for the test.
Determine if the proper gages are being used for the test.
Verify that the proper test fluid requirements and the proper
test gages are available.
Verify the setting of the test relief valve.
Different sections of the boiler may have to be tested

separately, if the design pressure of the sections is significantly
different. The test pressure should be based on the lowest
design pressure, if all the sections are tested at once.
20
Testing
The test procedure for each particular boiler should be followed.
Any deviation from the test procedure should have the proper
approval.
In general, the test procedure specifies:
Isolation of equipment. Make sure there is no fire in the

heater and all fuel lines are blanked. Remove safety relief
valves and blank off (isolate) the section to be tested.
Filling with test fluid. Care must be taken to vent out all the
air as much as possible, and fill from the bottom. The fluid
used is usually water with inhibitors. Use of the proper test
fluid is especially important when the heater contains
stainless or high alloy steels. Close all vents, once filling is
complete.
Raise the pressure gradually to the test level. Maintain the

pressure for a set time. The test pressure should not be
exceeded by more than 6% at any time. Water temperature
should not be less than ambient and never less than 70F.
This minimizes the possibility of catastrophic brittle failure of
heavy walled parts during the test. It also prevents confusion
between leaks and condensation on cold surfaces. The
maximum allowable temperature during hydrostatic testing is
120F.
Inspect for leaks. Equipment should never be hammer tested

during a pressure test.
Release pressure slowly. Drain the test fluid only after

opening the vent valves, to avoid pulling a vacuum on the
system.
Document the test and inspection. This documentation includes

the description of any repairs required to accomplish the
pressure test.
21
CORROSION RATES
A corrosion rate is determined using two measurements of wall
thickness taken over a period of time.
C =
tO - t A
x 1000
Time
where: C
Corrosion rate, mils/year
tO
Thickness at beginning of time period,

in.
tA
Thickness at end of time period, in.
Time
Time period, years
One mil is one thousands of an inch, so the corrosion rate

equivalent is:
1 mil/yr = 0.001 in/yr
35 mils/yr = 0.035 in/yr
The corrosion rate calculation is illustrated in Example Problem 1.
22
Example Problem 1
In October 1995, the wall thickness was 1.181 in. In April 1998, the wall thickness was
1.135 in. What is the corrosion rate?
C =
Time =
C =
C =
tO t A
Time
1000
30 months
2.5 years
0.046x1000
2.5
(1.181 1.135 )x1000

2.5
18.4 mils / yr
Remaining Life
The remaining life calculation uses the remaining corrosion allowance and corrosion
rate.
RL =
where:
RCA x 1000
C
RL
= Remaining life, years
RCA
= Remaining corrosion allowance, in.
= Corrosion rate, mils/yr
The remaining corrosion allowance is simply the last measurement minus the minimum
thickness.
where:
RCA
= t A - t min
tA
Actual last measurement of wall thickness, in.
tmin
Minimum thickness, in.
The remaining life calculation is illustrated in Example Problem 2.
23
Example Problem 2
In the last sample problem, if the minimum thickness was 1.095 in., what is the
remaining life?
Since corrosion rates are not always constant, an inspection should be scheduled
sooner than the 2.1 years of remaining life. If the corrosion rate can be checked on line,
it should be scheduled for about th of the remaining life. If a turnaround is required,
the next inspection should be about of the remaining life. If RL limits the run length
before the next turnaround, replacement of the equipment should be evaluated.
24
PZV SAFETY RELIEF VALVES

Saudi Aramco has a pressure relief valve program that tracks all
pressure relief valve use and monitors their testing and
inspection. Pressure relief valve routine test inspection, quality
assurance and regulation is covered by GI 447.003.
Bench Test
The ASME code requires testing of boiler PZVs once per year.
This test is done by shutting down the boiler and removing the
PZVs. The PZVs are tested on a test bench. The PZV should
pop within the lesser of 10 psi or 3% of the relief setting. The
PZV should close tightly at no less than 96% of the set pressure
(4% below set pressure).
Check the safety relief valve records to make sure GI 447.003
and ASME Section 1 requirements are met.
The boiler safety relief valves are tested in-place annually. A
visual inspection that includes a check for leakage and vibration
damage should follow each operation of the safety relief valve
An approved written procedure must be in place to test safety
relief valves on-line.
A qualified and certified PZV technician performs testing and
inspection. Bench test and inspection is documented in the PZV
Maintenance Report Form 3750. Both pop and leak tests are
performed on the bench. Disassembly and inspection of the
PZV is required at the third consecutive PZV operating interval
(3 years for boilers).
25
Pressure Test
All boiler PZVs must be tested in place for the final set pressure
and blowdown (reseating) adjustments as required by the
ASME code. The in-place test is performed as per a written
approved operating procedure. The in-place test has provisions
to prove full lift capacity and accuracy of adjustments. The inplace test is reported on the same form 3750 as the bench test.
Additional in-place pressure tests may be required for boilers
over 400 psig depending on operating experience as
recommended by the National Board Inspection Code. The
National Board Inspection Code recommends testing boilers
less than 400 psig every 26 months.
26
BOILER CHEMICAL CLEANING

SAEP-1025 gives the following criteria to determine when to
schedule chemical cleaning, based on the deposit density from
a tube sampling.
Deposit Present
Recommended Action
Less than 250 g/m2
No requirement to chemically clean
250-500 g/m2
Schedule cleaning within 1 year
500-1000 g/m2
Schedule cleaning within 3 months
Over 1000 g/m2
Chemically clean before operating
SAEP-1025 gives the following criteria for evaluating the

effectiveness of chemical cleaning based on the deposit density
from a tube sampling.
Deposit Present
Recommended Action
10 g/m2 or less
Excellent
>10 or <20 g/m2
Good
>20 or <30 g/m2
Average
>30 or <50 g/m2
Passing
>50 g/m2
Not Acceptable
27
Requirement and Recommendations

The data from inspection of deposits is used to determine if
there is a need for chemical cleaning. Chemical cleaning is not
routine maintenance but only done on an as-required basis.
With proper boiler operation, chemical cleaning is not normally
necessary.
Boiler deposits are primarily calcium and magnesium carbonate
salts that have deposited in the tubes and drums because the
salt concentration was too great in the boiler circulating water.
These salts are removed by chemically cleaning with an
inhibited acid followed by neutralization and passivation of the
metal.
The scale deposits from tube sampling are used to determine
exactly what specific chemical treatment will be employed in
chemical cleaning for a boiler.
If the condensate return was contaminated with oil, the oil must
be removed from the boiler, prior to chemical cleaning for it to
be effective. Oil is usually removed by an alkaline boil-out for
light oil contamination and an alkaline permanganate boil-out for
heavy oil (crude) contamination. The alkaline boil-out uses
caustic soda and the alkaline-permanganate boil-out uses a
mixture of caustic soda and potassium permanganate.
Superheaters and economizers are not normally chemically
cleaned because there should be no water in the superheater,
and the concentration of salts in the economizer should be very
low. Superheaters may require chemical cleaning, if there has
been significant carry over from the steam drum or, if an
attemperator is installed. An attemperator adds water to the
superheater to control the outlet temperature.
Steps
The procedure for chemical cleaning of boilers at the Abqaiq
Utilities Plant is attached as Addendum B. This procedure is
typical of chemical cleaning procedures since it follows General
Instruction GI 402.001.
The boiler chemical cleaning procedure is divided into the
following sections:
28
Preparation
Preparation for chemical cleaning of boilers include:
Installation of blinds on inlet and outlet from the steam drum.
Removal of screen and baffle plates from the steam drum.
Installation of temporary pressure, temperature and level

gages.
Blinding of all level gages and instrument lines, except for

the instrumentation and gage glasses installed for chemical
cleaning.
PZVs are removed from the steam drum and temporary

vents are installed.
Temporary connections to the mud drum are installed to add

and remove chemical cleaning solutions.
Alkaline Boil Out
Alkaline boil out includes adding chemicals to boiler water and

firing the boiler slowly until the pressure reaches 200 psig. Hold
200 psig pressure for 24 hours. Then drain the boiler and open
for inspection.
Acid Cleaning
Acid Cleaning includes filling the boiler with condensate and

lighting off the boiler (one burner) to raise the temperature of the
boiler to about 180F. Drain and refill with condensate and acid
cleaning chemicals. Circulate the chemical for 4 to 6 hours and
drain. Repeating the above procedure may be required
depending on the amount of scale in the boiler.
Neutralizing and
Passivation
Neutralizing and passivation includes filling with a sodium

carbonate solution, lighting off one burner, maintaining a 200
psig pressure for 2 hours, and draining the boiler when
temperature is below 200F. This procedure is done to
neutralize any traces of acid and to lay down a coating to
minimize stress cracking.
29
WORK AIDS
WORK AID 1:
RESOURCES USED TO CALCULATE CORROSION

RATE AND REMAINING LIFE
This Work Aid is to assist in Exercise 1.

Part 1
In October 1996, the wall thickness was 1.181 in. In April 1998, the wall thickness was
1.135 in. What is the corrosion rate?
C =
Time =
C =
C =
tO t A
Time
1000
30 months
2.5 years
0.046x1000
2.5
(1.181 1.135 )x1000

2.5
18.4 mils / yr
The remaining life calculation uses the remaining corrosion allowance and corrosion
rate.
RL =
where:
RCA x 1000
C
RL
= Remaining life, years
RCA
= Remaining corrosion allowance, in.
= Corrosion rate, mils/yr
Part 2
In the last sample problem if the minimum thickness were 1.095 in., what is the
remaining life.
RCA = 1.135 - 1.096 = 0.039 in.
RL =
RCA x 1000 0.039 x 1000

=
C
18.4
RL = 2.1 yrs.
30
GLOSSARY
austenetic
Type of steel alloy (stainless steel) that has a tendency to

stress cracking corrosion.
design pressure
The maximum pressure for which a piece of equipment was

designed to operate.
fiber scope
Long (up to 100 ft.) fiber type remote viewing and/or TV

device for internal inspection.
fluxing
Reacting refractory with metal oxides that may result in

compounds that are liquid at operating conditions of the
heater.
maximum allowable
pressure
This is the maximum pressure at which a boiler is allowed to

operate. It is also the pressure used to design the boiler.
neutralization and
passivation
A metal treatment to eliminate any traces of acid and lay

down a film to minimize stress cracking.
PZV
Safety valve.
safety relief valve
A device which opens automatically at a set pressure to

relieve pressure. Safety valves are used in vapor service.
scale
Deposits in boilers, primarily calcium and magnesium

carbonate salts.
slagging
Reacting refractory with metal oxides that may result in

compounds that are liquid at operating conditions of the
heater. Slagging is the flow of the liquid formed.
31
ADDENDUM
Section
ADDENDUM A:
ADDENDUM B:
ADDENDUM C:
ADDENDUM D:
Page
BOILER LAY-UP PROCEDURES......................................... 33

ABQAIQ CHEMICAL CLEANING PROCEDURE.................. 35
STANDARDS FOR BOILER INSPECTION........................... 49
HOW TO MAKE A BOILER FIRESIDE INSPECTIONS ........ 55
32
ADDENDUM A: BOILER LAY-UP PROCEDURES
33
34
ADDENDUM B: ABQAIQ CHEMICAL CLEANING PROCEDURE
35
36
37
38
39
40
41
42
43
44
45
46
47
48
ADDENDUM C: STANDARDS FOR BOILER INSPECTION
49
50
51
52
53
54
ADDENDUM D: HOW TO MAKE A BOILER FIRESIDE INSPECTIONS
55
56
REFERENCES
SAES-F-008
Chemical Cleaning of Boilers
SAER-5440
GI 402.001
ASME Boiler and Pressure Vessel Code
57

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Saudi Aramco DeskTop Standards

BOILER INSPECTION, PRESSURE TEST

For additional information on this subject, contact

Saudi Aramco DeskTop Standards

Bench Test ......................................................................................................... 25

Saudi Aramco DeskTop Standards

Saudi Aramco Engineering Standards (SAES)

General Requirements for Pressure Testing

Safety Instruction Sheets

Hydraulic Testing Fluids and Testing

Pressure Relieving Devices

Other Saudi Aramco Standards

Pressure Testing Safety

Pressure Relief Valves

Safety Relief Valve Test, Inspection and

General Instruction on Chemical Cleaning

Chemical Cleaning of Boilers

Mothballing/Lay-up Procedures for Boilers

Boiler and Pressure Vessel Code

ASME Section VII

Guidelines for the Care of Power Boilers

National Board Inspection Code

Inspection of Pressure Vessels

Inspection of Fired Boilers and Heaters

Inspection of Piping, Tubing, Valves

Inspection of Pressure Relieving Devices

Saudi Aramco DeskTop Standards

PREPARATION FOR INSPECTION

Original Design Drawings

Piping and Instrumentation Diagrams (P&IDs)

Safety Instruction Sheets (SIS)

Hydrostatic Test Diagram

Previous hydrostatic test results

The original design drawings and the P&IDs provide information

Saudi Aramco DeskTop Standards

The boiler log provides a record of each inspection,

Saudi Aramco DeskTop Standards

EXTERNAL BOILER INSPECTION

Ladders, stairways and platforms

Air and flue gas ducts

Boiler support structure

Support structure & boiler casing

Safety relief valves

Paint and insulation

Boiler circulating pumps

Vents and drains

Saudi Aramco DeskTop Standards

Ladders, Stairways and Platforms

Cracks - Inspect welds and structural steel for cracks.

Tightness of bolts - Bolt tightness can be determined by

Condition of paint or galvanized material

Wear on ladder rungs and stair treads. Inspect depressions

Security of handrails - Inspect for broken braces, supports,

The condition of flooring - Check for any unsafe conditions.

Saudi Aramco DeskTop Standards

Air Ducts and Flue Gas Ducts

Support Structure and Boiler Casing

Saudi Aramco DeskTop Standards

All foundations settle to some extent. Little or no trouble may be

Saudi Aramco DeskTop Standards

Paint and Insulation