Measures taken to reduce the hazards ensuring the safe and reliable working Remnant Life Assessment ( RLA ) of boiler pressure parts,also a legal requirement for unit,which have completed 1 lakhs operating hours OR 15 years in service, which ever is earlier. Inspection and certification of the safety valves
Measures taken to reduce the hazards ensuring the safe and reliable working Conditioning monitoring of the boiler by using NDT Techniques like inspection of deposits in tubes of different sections,hardness testing,Dye penetrate and ultrasonic testing of weld joints. Trivi test; by increasing drum pressure
Measures taken to reduce the hazards ensuring the safe and reliable working Destructive testing of sample tubes during overhaul of boiler.( tensile test ) Regular monitoring of tube thickness,tube scanning and advance techniques like LFED ( Low frequency Electrodynamic Device.)
Measures taken to reduce the hazards ensuring the safe and reliable working Ensuring proper protection by periodic checks by simulating or relevant procedures.( At the end of the outage simulating scenarios / faults & checking MFT and checking healthy working of protection.) Hydro testing of boiler once in a year
Controls for boiler in service - Permissive for boiler purging prior to lightup.( By using FD&ID fans to clear all explosive mixture if any) Flame scanners-for detecting the flames of the burners.( Sensing the flame by UV sensors) Furnace draft control to avoid explosion / implosion of boiler / ductings. Various other controls for monitoring feed flow,combustion control etc
Controls for boiler in service - Acoustic sensors to detect the sound of the tube leak in the furnace. Alarms and monitoring and controls to maintain the water chemistry. Alarms and monitoring metal temperature of pressure parts.( Water chemistry,pH value,unwanted chemicals such as Silica) Gas Leak detection system in the firing aisle of boiler and near gas station.
Controls for boiler in service - Regular house keeping reports and checks. Provision for installing the rupture disc in coal mill inlet air ducts is in progress (Inside coal mill air inlet duct as certified by NFPA ).