Aalborg MISSION ORC Waste Heat Recovery

Visual inspection of gas side for soot buildup, exhaust temperature measurement: >10-20°C above setpoint indicates sludging; perform water flushing kit application (50 l/min, 0.4-0.6 MPa pressure); operate Soot-Blower daily 3x (caution: In case of uptake fire DO NOT blow down with steam due to H₂ fire hazard)

Internal inspection test (opening of sight glasses/hand ports): inspect tubes for wear, pitting, thinning; external inspection for soot deposits, blistering, sag; perform hydraulic pressure test at 1.25 × operating pressure for maximum 10 minutes

Class surveyor: Inspect all boilers >3.5 bar working pressure and >4.65 m² heating surface. Frequency: DNV/LLOYDS every 2 years up to 8 years old, then annually; 2 comprehensive internal inspections per 5-year period, interval maximum 36 months. Inspect internal surfaces (drums, headers) for sludging, corrosion, cracks.

Safety valve test: opening at ≤3% above working pressure; test pressure 15% above working pressure for maximum 10 minutes (feedwater only for water level safety); pressure rise during test maximum 10% above design pressure at full load firing with stop valves closed.

Sight glass visual inspection for highest, lowest, normal water level markings; protective devices without sight obstruction; test water cushion safety ball valve for function; check drain line for safety.

For Aalborg OL/D and similar burner boilers: inspect refractory material (membrane walls, furnace floor) for cracks, deformation, separation; remove carbon deposits. For XS-TC7A: clean helix tube bundle with water flush kit (7–8 hours on similar ships), if necessary add cleaning chemicals before discharge to slop tank.