INSPECTION OF FIRED HEATERS
For Furnace Coils/Tubes.
Visual Inspection:
After cleaning, the entire heating coils (radiation and convection) shall be given a
thorough visual inspection to identify effects of deterioration, actual and potential
defects on tubes, fittings and cross overs. Refractory areas behind the tubes shall be
inspected using a mirror.
Following should be checked during visual inspection:
a. Sagging, bowing or distortion.
b. Bulging caused by loss of structural strength.
c. Oxidation and scaling.
d. Cracks, creep lines etc.
e. External corrosion / pitting / grooving.
f. Tube end erosion / thinning. (Where accessible).
g. Tube supports / hangers / tube sheet for oxidation & cracks.
h. Return headers for corrosion, erosion & cracks.
Special attention should be given for the following:
a. All welds and heat affected zones.
b. Tube surfaces adjacent to the burners.
c. Entry and exit points through tube sheets of inlet and outlet tubes
and tubes headers. Stainless steel and alloy steel headers shall be
checked for cracks after removal of insulation.
d. Junction of plain and finned/studded section of convection tubes.
e. Tube surface at the location of tube support and hangers.
f. Location of skin thermocouple pad welds.
g. Location of injection points.
INSPECTION OF FIRED HEATERS
❖ Visual inspection of welds shall be done randomly after cleaning.
❖ Tubes sagged/bowed by more than 5 tube diameters should be
replaced.
Where internal inspection of tubes is possible, inspection can reasonably
identify, the following: -
1) Pit type corrosion or local corrosion.
2) Thinning at tube ends.
3) Erosion.
4) Coke/scale deposits.
Inspection of radiation and convection coils of a heater is carried out in similar
manner. However, inspection of convection coil is limited to the accessible
tubes. Convection coils shall be checked carefully for external corrosion as
these are more prone to external corrosion than radiation coils.
In convection sections, sagging of the tubes in upper rows to a point between
those in lower rows can prevent the free passage of flue gas around the tubes.
This condition, called nesting, will result in overheating of adjacent tubes and
draft loss. If this condition is found, the offending tubes should be replaced.
Sample U-bends of convection section may be cut for visual inspection & I.D
measurements.
Heater tubes should be checked for grooving or mechanical damage at the
location of tubes supports / hangers / tube sheets.
Prepared by,
Rajesh Pillai.
Sr. Engineer Inspection.
