Scope of Work

1. Supply & Erection of scaffolding (inside & outside).

2. Removal and re-application of insulations, wherever required
3. Removal and re-application of refractory, wherever required
4. Cleaning and surface preparation for non-destructive testing by buffing or
grinding process as the case may be.
5. Gas cutting of boiler shell plates, stiffeners, structural etc. wherever
required for removal of insulation / refractory to carry out NDT and rewelding of the shell plates (New plates/ old plates) stiffeners, structural
etc. to the original location as per the instruction of the engineer in
charge.
6. Removal of dust, sludge etc. from tube, furnace, economizer etc. and to
dispose to a place as instructed by the Engineer-in-Charge.
1. Supply & Erection of Steel Scaffolding Inside and Outside
Steel scaffolding is to be made out of tubular structures (standards
scaffolding pipes of 40mm dia and clamps) in order to make entire inner
surface of Main Boilers (2 Nos) (furnace area, convection tube area, Boiler
steam drum, Mud drum and economiser area) safely accessible for
cutting and removal / fixing and re-welding of boiler shell plates,
removal / application of insulation, removal / application of refractory,
visual inspection, non-destructive testing (NDT) work and video
Boroscopy.
Working platform or stages are to be made by Steel grills / Aluminium
Perforated Sheets/ grills or similar material and secured firmly. These
platforms are to be provided at a vertical distances of about 1200mm
below each welding joint of the tube / header / Drum to enable visual
inspection and NDT work of these welds and surfaces conveniently while
inspecting personnel are standing on the platform/stages. Similar stages
are to be made inside (furnace) and outside the boiler furnace,
convection tube area, Boiler steam drum area, Mud drum area and
economiser area for the inspection and NDT of all the weld joints and
plates. Platforms are also required to be built for inspection of all nozzles
welds.
2. Removal of Insulation:
a. Remove 100% insulation of steam drum, mud drum, BFW inlet header
and Main Steam outlet header.
b. For all other connected piping, remove insulation up to first block valve
from the boiler.
c. Open 100% insulation for all drain and vent lines.
d. Extra insulation shall be removed wherever required as deemed
necessary as per the instructions of the engineer-in-charge.

e. Number of locations to be exposed may vary depending on actual

requirement. Provision must be kept for the same.
3. Re-application of Insulation
On completion of inspection, thermal insulation shall be re-applied by the
Contractor as per HPCL Specifications.
4. Cleaning & Surface Preparation for Non Destructive Testing
All appropriate tools (grinding machines, buffing wheels of different
grades, emery wheels of different grades, emery tape, files etc., tackles
and any other consumables required for the internal and external surface
preparation and cleaning as enumerated in the following paragraphs shall
be arranged.
List of NDTs to be carried out during RLA is as follows:
Visual Inspection
UT Flaw Detection,
Wet Fluorescent Magnetic Particle Inspection,
Dye Penetrant Testing,
Ultrasonic Thickness Measurement and OD Measurement,
In-situ Metallography (Replilca) and
Hardness Measurement
Cleaning of surfaces is to be done by buffing.
The surface finish to be of maximum finish (white metal finish) for carrying
out the above inspections.
The locations to be buffed will be intimated at the time of execution.
The quality of buffing should be to the satisfaction of Engineer in charge.
Cleaning shall be done by using mechanical striking tools, chipping
hammers, emery paper, buffing wheels, grinding wheels or rotating wire
brushes or by any other better and safe technique.
The detached rust, mill scale etc. shall be removed by clean rags.
1. The dimension of the spot to be prepared for UT Flaw detection is
throughout the length of the weld with 200mm parent metal on either
side of the weld.
2. The dimension of the spot to be prepared for WFMPI and DP Test is
throughout the length of the weld with 150mm parent metal on either
side of the weld.
3. The dimension of the spot to be prepared for Thickness Survey is 2
dia size.
4. The dimension of the spot to be prepared for Metallography and
Hardness Test is 2 2 size.

Visual Inspection
The area for visual inspection to be cleaned thoroughly (Loose scale, oil, dirt,
sludge etc. shall be removed from surface) as per the requirement of the
inspection agency and the Engineer-in-charge and also to provide assistance
for carrying out the visual inspection on the following areas.
a) Steam Drum
b) Mud (Bottom) Drum
c) Economizer Return bends
d) Main Steam Header
e) Economizer inlet and outlet headers
f) BFW inlet line
g) Boiler Bank Tubes (Convection)
h) Main Steam header

UT Flaw Detection: The area to be inspected is to be buffed with electric

buffing machine.
a) Steam Drum:
Inside
100% of the welds including circumference and longitudinal seams,
all butt welded joints and welds of the dish ends are to be checked
by angle probe scanning for UT FLAW DETECTION.
b) Mud (Bottom) Drum:
Inside
100% of the welds including circumference and longitudinal seams,
all butt welded joints and welds of the dish ends are to be checked
by angle probe scanning for UT FLAW DETECTION.
c) Main Steam Header:
100% of the butt welds joints to be done with suitable probe.
d) Economizer inlet and outlet headers
100% of the butt welds joints to be done with suitable probe.

e) BFW Inlet line:

100% of the butt welds joints to be done with suitable probe.

Wet Fluorescent Magnetic Particle Inspection

a) Steam Drum
Inside
100% of the welds including circumference and longitudinal seams,
nozzle welds, welding spots/areas of temporary attachments i.e.
brackets, clamps, cleat etc. 100mm parent metal on either side of
the weld.
Outside
Fillet welds of supports, reinforcements in the dish ends and
legs/stub to reinforcement pads (if any) are to be checked by
WFMPI.
Nozzle to shell welds and reinforcement pads including manhole
welds to be checked from outside by WFMPI.
100mm of parent metal on either side of the weld is to be covered
in WFMPI of welds.
b) Mud Drum
Inside
100% of the welds including circumference and longitudinal
seams, Downcomer, nozzle welds, welding spots/areas of
temporary attachments i.e. brackets, clamps, cleat etc.
Outside
Fillet welds of supports, reinforcements in the dish ends and
legs/stub to reinforcement pads (if any) are to be checked by
WFMPI.
Downcomer, Nozzle to shell welds and reinforcement pads
including manhole welds to be checked from outside by WFMPI.
100mm of parent metal on either side of the weld is to be covered
in WFMPI of welds.
f) Economizer inlet and outlet headers
100% of the butt welds joints, welding spots / areas of temporary
attachments.
c) Economizer header(top & Bottom)
100% of the butt welds joints to be done.
d) BFW inlet line:
100% of the butt welds joints, welding spots / areas of temporary
attachments.
Dye Penetrant Testing

a) Steam Drum
Inside
100% of the welds including circumference and longitudinal seams,
nozzle welds, welding spots/areas of temporary attachments i.e.
brackets, clamps, cleat etc.

Outside
Fillet welds of supports, reinforcements in the dish ends and
legs/stub to reinforcement pads (if any).
Nozzle to shell welds and reinforcement pads including manhole
welds.
b) Mud (Bottom) Drum
Inside
100% of the welds including circumference and longitudinal seams,
Downcomer, nozzle welds, welding spots/areas of temporary
attachments i.e. brackets, clamps, cleat etc.
Outside
Fillet welds of supports, reinforcements in the dish ends and
legs/stub to reinforcement pads (if any).
Downcomer, Nozzle to shell welds and reinforcement pads
including manhole welds.
c) Economizerinlet and outlet headers:
Butt weld joint where accessible.
d) Main steam Header
Outside
100% of the butt welds joints, welding spots / areas of temporary
attachments.
e) BFW inlet line:
100% of the butt welds joints to be done.
In-Situ Metallography (Replica)
a) Steam Drum
Inside & Outside
5 Points.
b) Mud (Bottom) Drum
Inside & Outside
5 Points.
c) High temperature Headers (Top headers) (2 Nos.)
2 Points per header (4 Points).

d) Water Wall Tubes Furnace Tubes

2 Points
e) Steam Pipe
2 Points.

Video Boroscopy / Fibre Optic Inspection: For evaporator tube

inspection.

Ultrasonic Thickness Measurement and OD Measurement

a) Steam Drum
40 points.
Mud (Bottom) Drum
40 points.
b) Economiser
50 points.
c) High temperature Headers (Top headers) (2 Nos.)
10 points.
d) Economiser header (top & Bottom)
10 points.
a) Boiler Bank Tubes (Convection)
50 points.
b) Water Wall Tubes Furnace Tubes
300 points.
c) Steam Pipe
20 points.
Hardness Measurement
a) Steam Drum
20 points.
b) Mud (Bottom) Drum
20 points.
c) High temperature Headers (Top headers) (2 Nos.)
16 points each header.
d) Water Wall Tubes Furnace Tubes
8 points.
e) Steam Pipe
8 points.