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HARRIS PYE SINGAPORE PTE LTD

FPSO “GLAS DOWR”

BLUEWATER ENEGY SERVICES B.V.

Inspection Report on Condition of

Steam & Water Drums of MAC-45B Boiler

October, 2010

Harris Pye Singapore Pte Ltd. Tel : (65) 6863 3188

17 Gul Street 4 Fax : (65) 6863 3166
Singapore 6292242 E-mail : boiler@harris-pye.com.sg

Website : http://www.harrispyegroup.com
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Contents

Section 1 Introduction

Section 2 Inspection of Steam / Water drum internal

Section 3 Conclusions

Section 4 Recommendations
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Section 1 Introduction

Harris Pye Singapore attended the vessel FPSO “GLAS DOWR” to carry out an inspection of the
steam and water drum internal condition at Sembawang shipyard, Singapore at request of Bluewater
Energy Services B.V.
The inspection comprised of the following elements.

1) Visual inspection of steam and water drums internals with photographic documentation using
digital camera.

2) Ultrasonic thickness gauging for the drums including tube plate and dish ends using Third
Party inspectors.

3) Random MPI of longitudinal and circumference welding seam of steam and water drum using
third party inspectors.

4) MPI of the welding seams of plugs of rear bank tubes and surrounding plate using third party
inspectors.

Inspection Details
Date of Inspection : 14th October 2010
Location : Sembawang Shipyard, Singapore
Inspection Type : Visual
Equipment Used : Digital camera

Inspection Team
Hideki Terao : Boiler Engineer (Harris Pye)
Ken Irawadi Sidharta : NDT Inspector (Matcor)
Myo Aye : NDT Inspector (Matcor)

Boiler Technical Data

Manufacturer : Mitsubishi Heavy Industries, Ltd
Type : MAC-45B
Boiler number : 3594
Boiler design Pressure : 18.0 kg/cm2
Operating pressure (S/H outlet) : 16.0 kg/cm2
Evaporation : 45,000 kg/h
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We trust the following report is to your satisfaction. Please do not hesitate to contact the undersigned
if further clarification is required.

HARRIS PYE SINGAPORE PTE LTD

Hideki Terao
Sales Engineer
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Section 2 Inspection of Steam/Water Drum internal

STEAM DRUM

Steam drum internal was visually inspected.

All of the internal attachments were removed when the inspection was carried out, so the inspection
was limited to the drum itself, tubes and headers connected to the drum.

A lot of pitting and corroded surface was observed throughout the steam drum. Most of the pitting
sighted was sharp and specific and typical of “Oxygen” scab type pitting. However few scabs were
sighted so at some time the boiler had been cleaned to remove scabs most likely in service. There was
some general corrosion quite heavy in places but nowhere sighted did this amount to any relevant
material lost. The worst of this corrosion was around and below normal water level. The pitting was
existed and the depth of the some of deepest one was approximately 3-4 mm.

There had been 6 number of rear bank tubes failure in the past and been plugged. The plugs were
welded to not only tubes but also to the inner drum surface.

Ultrasonic thickness gauging was carried out to confirm the thickness of drum shell and dish end
generally. The result of reading for the thickness is reported separately by the third party NDT
inspectors.

Magnetic particles inspection was carried out for 100% of longitudinal and circumference welding
seam of the drum as well as welding seam of 6 numbers plugs and drum shell plate surrounding them
to ensure cracks free. The result was good and would be reported separately by the third party NDT
inspectors.
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General view of the steam drum internal – Attachments were removed.

General view of the tube plate and the rear bank tubes

Close up view of the tube plate (drum shell)

Corroded surface could be observed on the large area.
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Close up view of the drum shell

Pitting was existed.

Close up view of the drum shell

The depth of this kind of pitting was approximately 2-3 mm.
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Close up view of the drum shell

One of the deepest pitting as depth was approximately 3-4 mm.

Corroded surface of drum shell plate near the normal water level
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Plugs of the rear bank tubes which welded to the drum internal surface

MPI was performed to circumference and longitudinal welding seam

Please see separate report for the result and detail.
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WATER DRUM

Water drum internal was visually inspected.

General condition of the water drum was apparently worse than the steam drum. Deeper “Oxygen”
pitting and general corroded surface were observed throughout the water drum especially lower half of
the drum shell. The sharp pitting was existed and the depth of the some of deepest one was
approximately 6-7 mm. There were a few scabs still intact but mostly pits visible and free of active
corrosion.

One location of deep and large “cutting mark” was appeared near the bottom blow down pipe. The
reason of this cutting mark was unknown however it was look like ground. It is our opinion this mark
has been there from construction. There is no active corrosion associated with it and the through
penetration construction method renders it insignificant.

There had been 6 number of rear bank tubes failure in the past and been plugged. The plugs were
again welded to not only tubes but also to the inner drum surface.

Ultrasonic thickness gauging was carried out to confirm the thickness of drum shell and dish end
generally The result of reading for the thickness is reported separately by the third party NDT
inspectors.

Magnetic particles inspection was carried out for 100% of longitudinal and circumference welding
seam of the drum as well as welding seam of 6 numbers plugs and drum shell plate surrounding them
to ensure cracks free. The result was good and would be reported separately by the third party NDT
inspectors.

General view of water drum

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Photo shows the tube plate (drum shell) and tube end of rear bank.
Much scale could be seen.

Deeper pitting on the drum shell

A written yellow numbers are approximate depth of pitting measured by caliper.
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Close up view of pitting

Close up view of pitting

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Pitting on the welding seam

“Cutting mark” near the bottom blow down pipe by unknown reason
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MPI for welding seams and UT thickness gauging was done by third party

Section 3 Conclusions
1) The boilers at some time in the past have been operated with Poor water quality and high levels
of dissolved oxygen

2) The unit has obviously been observed to have scab type pitting and been cleaned at some time
in the past as active scabs were not generally present

3) The six pieces of plugged and welded tubes most likely made in service appear to be made by
ships staff or inexperienced contractors as general appearance the welding is poor quality and
methodology would not follow good boiler making practice.

4) General drum condition is acceptable for trading use

5) With the proviso of long term service it may be prudent to address the deepest pitting in the
water drums and the “Grinder Mark” at the drain hole

6) With regard the NDT (Matcor) inspection and general drum thickness report all readings are
well within the acceptable range and no defects warrant discussion.
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Section 4 Recommendations
1) Remove the 12 welded plugs and complete the drum inspections by applying NDT after
removal

2) If drum integrity is confirmed in these areas power brush both steam and water drum
internal surfaces and dig out the few sighted scabs to expose all pitting.

3) Make repair schedule for Steam & Water drum pitting

4) Make approval to Class for repairs proposed

5) Carry out the repairs

6) Hand the boiler for re-tubing