Meet Nancy Miller!
It’s always good to have new faces and helpful hearts on the team. We’re proud to introduce Nancy Miller, the newest addition to BPC! We look forward to getting to know you more Nancy! Keep reading to learn more about Nancy and what she’s contributing to our team.
How long have you been with BPC, and what did you do before this position?
I started with BPC on February 26, 2024, and previously I worked as a Senior Office Administrator for a local company.
What are you looking forward to most about working at BPC?
I’m looking forward to learning about the industry and getting to know everyone.
Who inspires you professionally; do you have any mentors?
I have two… both were previous Directors. They were wonderful in supporting their employees and being open to trying new things that made everyone’s job (if not easier) at least more enjoyable!
What’s your most-used productivity hack?
Excel – I think it’s a wonderful tool that can do so much to help make a company or employee more efficient.
Tell us about you (whatever you’d like to share that makes you YOU.)
Like everyone, I enjoy spending time with family. I have family up and down the East Coast so when we get together it’s that much more enjoyable! As for hobbies, I like to dabble in many crafts but I enjoy reading, knitting, encaustic painting and bookbinding the most.
How do you feel about joining the BPC team?
I’m excited to join the team and learn more about the industry. I believe that my past experiences have given me the skills to help me succeed with BPC.
What kind of music do you like, and what’s the best concert you’ve been to?
Anything I can dance to! Interestingly enough I’ve never been to a concert… but I wish I had seen Tina Turner and Prince.
What’s the best place you’ve traveled to?
So far, the Oregon coast. My family and I had a wonderful time just wandering on the beaches.
What’s your favorite food?
Pasta! I don’t eat it often, but if I could eat it without any health concerns I’d eat it every day!
What’s your favorite movie?
The Jurassic Park series; I’ve watched those movies a LOT.
Internal Inspection Of Supercritical Pressure Utility Steam Generators
A supercritical steam generator operates above a critical pressure of about 3,200-3,900 psi and temperature range of 538-565o C. At this pressure and temperature, water vapor is directly converted to the steam phase without going through the saturated steam phase. Consequently, a steam drum is not required.
In a subcritical boiler, the steam produced is in a saturated state and has to be heated further through a superheater to produce superheated steam. Therefore, subcritical boilers require a steam drum. Typical steam parameters used in sub-critical reheat steam plants are 2400 psi and a temperature range of 374o C.
The internal inspection procedures of supercritical pressure steam generators, including coal-fired units, shall be further discussed; although several procedures are also common to internal inspection of subcritical boilers.
Safety is the top priority for internal inspection, especially if the boiler is entered before cleaning. Most areas of the steam generator require crawling in tight spaces and confined space entry training and permits.
Since the steam generator is several stories high, inspection could start from the penthouse downwards or from the lower furnace upwards, crawling where possible through the inspection ports and duct holes to get a good visual inspection view.
In the furnace, scaffolding is installed to access the higher areas. The newer methods of inspection of large boilers involve the use of drones. Drones are designed with state-of-the-art sensors, oblique lighting and image-capturing systems to take images from several angles. Images of hard-to-reach, and dark areas can then be transmitted in real-time for observation and documentation. Several companies provide these services and experienced pilots. safer evaluations of boiler systems. Eliminating the need for hazardous
The purpose of an internal inspection is to observe and document the actual mechanical condition of the components: wear patterns, cleaning patterns, alignment and mechanical issues of any sort – along with any signs of debris, foreign material, corrosion products, indications, etc. Localized concentration of corrosion products is typically the indication of a problem. A further investigation is warranted to determine the root cause and potentially prevent recurrence.
A general itemized checklist at-location is detailed below:
Penthouse
- Hanger rod corrosion and condition. Check for distorted and loose hanger rods.
- Roof seal condition
- Weatherproofing – lagging condition – joint integrity
- Penthouse floor. Inspect roof tube support clips when accessible.
- Seal xoxes and crown seals
- Tube penetrations
- Determine air washed areas, intensity of leakage as viewed from the boiler side
- Refractory condition
- Iso-membrane condition (if installed)
- Verify header wrapping and insulation condition
- Inspect all terminal tubes for overheat/creep exfoliation conditions.
- Inspect all header supports and connections for integrity.
Lower Furnace
- Note tube erosion and/or wastage (if any), and look for upper transition bends and lower throat bends for wear.
- Evaluate the lower slopes for quench cracking from possible bottom ash water splash.
- Inspect for possible gouged, crushed, sliced and dented tubes.
- Seal trough-bottom ash hoppers erosion/corrosion.
- Ash pit condition (refractory / general). In addition, inspect for jet nozzle condition and positioning.
- Check the ash hopper water seal (if applicable).
- Clinker grinder/Drag chain (if applicable)
- Sidewall and buckstay damage adjacent to and behind the lower slopes as a result of possible clinker fall
Mid Furnace
- Access doors
- Closure and seal
- Refractory (inside furnace)
- Wind Box casing
- Soot Blower lance penetrations
- Seals
- Refractory (inside furnace)
- Tube alignment, wind-box and furnace casing construction
Lower – Mid-Upper Furnace
- Tube alignment, wind-box and furnace casing construction
- Slag and fouling pattern. Identify unnecessary slag traps on waterwalls.
- Burner zone condition. Inspect for flame-impinged tubing.
- Furnace (lower slope and division wall. Identify all peg fin and membrane sections observed to exhibit fatigue and cracking.)
- Radiant section – note any or all blisters and bulges.
- Convection passes – look for erosion, corrosion, overheat and creep.
- Economizer – look for misalignment, clips, erosion and corrosion.
Dead Air Spaces
Lower Furnace.
- Note slope tube, I-beam support intersection for damage, including clip condition.
- Identify casing and membrane breach locations on the furnace side.
- Record ash accumulations and observe the condition of pressure part components for corrosion.
- Nose arch Apex. Inspect for casing and refractory breaches to the furnace side.
- Inspect all structural steel supports and beams for integrity due to potential overheating if breaches are found.
Fans (Forced Draft, Induced Draft, Primary Air, Seal Air, Gas Recirculation, Over-Fire Air – if boosted – and Burner Cooling Fans):
- Fan housing
- Fan wheel observations – fly ash erosion, tip cracks, loose bolts or rivets and rubs
- Inlet vanes – stroke, fly ash wear, linkage and bushings
- Inlet louvers outlet dampers – check stroke, fly ash erosion, linkage pins/bolts.
- Casing wear
- Blade condition
- Shaft seals
- Inlet and outlet ducts/joints
- Inlet Box Screens (if applicable)
- FD fan discharge duct, steam coils (if installed) cleanliness and condition
Wind Box/Secondary Air
- Synchronize secondary air dampers and verify operation from inside and outside damper.
- Drive limits and travel
- Burner tilts
- Linkages
- Draft gauges
Over-fire Air
- General condition
- Dampers and registers
- Tilt and yaw (tangentially fired units)
Ductwork (air ducts, gas ducts and economizer hoppers)
- Fly ash erosion
- Expansion joints
- Casing cracks – joint integrity and corrosion
- Ductwork supports
- Fly ash weight accumulation damage
Burners (Signs of erosion, physical damage and malformation)
- Mechanical tolerances
- Condition, centering (wall-fired)
- Tilt/Yaw adjustment (tangential fired)
- Igniters
- Air registers
- Nozzle condition
- Separated air zones
- Burner refractory
Access Doors
- General condition/closure
- Gaskets and sealing
Convection Pass
- Erosion baffles
- Gas lanes
- Casing and header penetrations
- Improved RH and SH damper control
Access Doors and Hatches (all)
- Closure, hinge and seals
Safety Relief Valves:
- Verify the safety valves are tested and comply with operating designed set pressures.
- Verify the method used for safety valves testing complies with ASME standards.
Repairs Review:
- If any welded repairs are completed, they should be approved and completed under the supervision of an Authorized Inspector (AI)
- NDT and/or hydrostatic test methods are as per AMSE B31.1 and witnessed by the inspector, or review of testing documentation is acceptable to the NB/Jurisdictional inspector.
