Renovation & Modernisation of Boiler

23 May 2012 PMI Revision 00 1

When to do R&M of Boiler?

R&M of Steam Generator is to be taken up under the following conditions: 1.The unit has logged more than 200,000 hours of operation, i.e. its design life 2.RLA report has indicated requirements of major replacements

3.The boiler is failure prone; e.g. frequent tube leakages

4.The boiler is not able to generate rated load 5.There is major off design performance; e.g. high metal temperatures, high flue gas exit temperature, high unburnt carbon 6.On grounds of environmental or safety considerations
23 May 2012 PMI Revision 00 2

Inputs for R&M

1. Condition Assessment (CA) & Residual Life Assessment (RLA) Studies 2. Thermal Performance Test (TPT), If Necessary

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PMI Revision 00

CA & RLA Studies

23 May 2012

PMI Revision 00

Intent of RLA
Restoration / up-rating of Generation capacity on a continuous, safe and reliable basis. To increase unit availability and reliability on Sustainable basis to meet the current requirements like ABT. Achieving rated or better efficiency of the unit so that the COG remains competitive. Achieving an extended competitive plant-life of another 15 years at least. To improve safety of plant and personnel. To meet current statutory and environmental norms.

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PMI Revision 00

CA & RLA
REVIEW OF OPERATIONAL HISTORY OF EQUIPMENTS:

Details of start up and Shut down Operational Regime Maintained Duration and extent of parameter escalation Steam temperature and water Chemistry Observation During Planned Shut downs Replacements during routine maintenance and forced outages Detailed Metallurgical Analysis Analysis/Reports on premature failures

23 May 2012

PMI Revision 00

CA & RLA
Pre Outage Planning and Survey:
Record nameplate details & general description of all equipments Compilation of design details Review of these compiled data and assess the present condition of equipment /system

Hot Walk down Survey

Survey of the equipment / system while in operation Reference marking to be made in piping system, hangers & supports, buckstays,etc Identify and prepare a list of missing items in equipment / system

Cold Walk down Survey

Inspection for detection of any visible abnormalities Measurement of steam flow path, thermal clearance, fitting clearance, etc
23 May 2012 PMI Revision 00 7

CA & RLA
Visual Examination:
To detect signs of overheating of tubes, for swelling, blistering and warping To identify signs of corrosion or erosion To examine convection pass tube banks for detection of misalignment of tubes To assess condition of all headers for ligament cracks etc. To determine the condition of components in the penthouse including header supports and structural members To determine boiler setting integrity Examination of drum internals

Dimensional Measurement:
The components liable for deformation or distortion due to wear / creep namely, headers, pipes, hangers, support structures etc. are to be thoroughly cleaned and dimensions to be measured to compare with original / previous record.

23 May 2012

PMI Revision 00

CA & RLA
Videoscopic Inspection :
Videoscopic examination of all header internals. Digital photographs are taken of each header internal surface and each header / stub connection. Videoscopic examination determines the following: a) Internal cracks on headers/nipples/stubs/ ligaments b) Condition of internal cleanliness c) Oxide scale

Non-Destructive Tests :
Dye- penetrant Examination (DPT) Dye-penetrant examination using fluorescent dye are used for detection of surface crack / porosity / discontinuity of header ligament joints, pipe weld joints, attachment weld joints, valve body / spindle / seal etc.

23 May 2012

PMI Revision 00

CA & RLA
Non-Destructive Tests (Contd.):
Magnetic Particle Inspection (MPI) Magnetic particle inspection using wet fluorescent method shall be employed for detection of surface and sub-surface crack / discontinuity of header ligament joints, pipe weld joints, attachment weld joints, valve body / spindle / seal etc. In case of detection of any crack, the depth shall be measured with the help of crack depth meter based on electrical potential drop principle or ultrasonic principle

Ultrasonic Examination (UT) Ultrasonic Examination method shall be employed for detection of sub-surface crack, loose bonding, stress cracking or any kind of discontinuity mainly in the longitudinal and circumferential seams of the boiler drum, girdling loops of all high temperature tube panels, butt weld joints, attachment welds and stub joints of the steam & water headers & pipes etc.

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CA & RLA
Non-Destructive Tests (Contd.):
In situ oxide scale measurement It is a high frequency ultrasonic method which is to be carried out at various locations, especially in the tubes where the metal temperatures are maximum, in the platen & final superheater and reheater assemblies. Furnace Corrosion & Thickness Mapping Continuous tube OD scanning method based on low frequency electro-magnetic principle to carry out the detail thickness and corrosion mapping of all the accessible tubes in the furnace zone Metallographic Replication (RPL) Metallographic examination by portable optical microscope and surface replication technique are carried out to assess the present microstructure condition of the components subjected to damage due to creep, temper embrittlement, stress corrosion cracking and thermal fatigue (low cycle fatigue).
23 May 2012 PMI Revision 00 11

CA & RLA
Non-Destructive Tests (Contd.):
Hardness Testing Hardness testing of tubes, weld joints, headers, pipes etc. are carried out, wherever required, to ascertain any change in metallography and to find out residual stresses. Hardness measurement are to be compulsorily taken at the spots where replica has been taken In-Situ Chemical Analysis (CA) In-situ chemical analysis is to be employed for determining and categorizing the steel grade of various superheater and reheater coils with the help of instruments based on either Optical Emission Spectroscopy (OES) principle or radioisotope excited x-ray fluorescence analyzer.

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CA & RLA
Destructive Tests:
Tube samples and tube deposits from various boiler locations along with boiler drum deposit are collected for destructive tests. These are analyzed at reputed laboratories for: Stress rupture test for mechanical properties Microstructure evaluation to find out metallurgical degradation Chemical analysis of deposits

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Recommendations
After collection of the various data as discussed and analysis thereof remaining life of the boiler is calculated & recommendations are given accordingly.

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Thermal Performance Test

The broad objectives of the TPT can be summarized as follows: To evaluate the present thermal efficiency of the unit To establish the steam, water and flue gas temperature profile and heat balance over different sections of the boiler To establish flue gas velocity profile over different sections of the boiler To establish excess air and air ingress levels at different sections in the boiler, particularly air heater leakage.

To analyze the data collected and compare with predicted performance data
To identify shortfalls in performance and causes for the same.
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R&M of Boiler

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16

Boiler Downtime Matrix (A typical case)

Pressure Parts Failure Pattern of a Typical Boiler
Economiser 26% Sec. Conv. Sections 8%
23 May 2012

Pri S/H 7%

Platen S/H 7% Sec S/H 28%

Water Wall 11%

Re heater 13% PMI Revision 00

17

Interactive Issues
Reheater Temp. C ontrol Dampers Air Ingress C oal Q uality Deterioratio G as Temp. High G as Q uantity High M ill C apacity

C oal Requirement Higher

Flue G as Velocities Higher

PA Fan C apacity

S econdary S H & other / Pr. Parts

Economizer erosion

Air Preheater Erosion

S - PA Air A M ismatch

S econdary C ombustion

Burner Effectiveness Reduced

Tube M etal Temp.High

Boiler Efficiency

Tube Failures

S team Throughput Drop

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M ajor Boiler Issues

18

Issues, Causes & Solution

Issues
Poor Availability / Reliability * Pr. Parts Lower Efficiency Inadequate Steaming Parameters * Milling System Higher Generation cost Increased Emission Levels & SPM

Areas

* Operating Parameters * Boiler Losses

* Operation & Maintenance practices * Turbine steam demand

* ESP

* Spares Inventory

* Health of Pr. Parts * Fan Margins

* Burners

Reasons

* Obsolete Technology * Completed Design Life

* Higher unburnt

* Coal Quality

* Unavailability of genuine spares / OEM spares * Quality of spurious spares * Design deficiency in Turbine

* Increased Moisture in coal * Increase dry gas loss / air ingress

* Air Ingress

*Ageing of Pr. Parts

* Wear & Tear of Components

Remedies

* Replacement / repair of worn out parts

* Replacement of furnace with membrane panels * Pent house sealing with improved design

* Milling system upgradation

* Switch over to new technology

* Addition of more fields in ESP

* Replacement of Pr. Parts with new design

* O&M Management system *Turbine Retrofit

* Increasing the height of fields / adding parallel stream * Installtions of improved burners / Low Nox burners

Achievements post R&M

* Increased avalbty. * Improved PLF & PUF

* Improved Efficiency

* Restoration of Design Parameters

* Reduced downtime and maintenance * Reduction in generation cost

* Reduced emission levels

23 May 2012

* Life extension

PMI Revision 00

19

Issue Life Extension

Component Typical Life Limiting Factor Lead Time For Ordering Outage Required for Installation

HeadersCreep , Superheater & Thermal Reheater fatigue Pipes MS & RH Tubes-Furnace wall, Superheater & Reheater
23 May 2012

2 3 years 13 weeks (large headers),6-9 weeks (small headers) 10-12 weeks (for complete superheater or Reheater units)
20

Fireside 18 months corrosion, Creep, overheati ng

PMI Revision 00

Issue Life Extension

Component Typical Life Limiting Factor Ash erosion Lead Time For Ordering 18 months Outage Required for Installation

Tubes Economiser coils, S-panel etc. High Pressure Valves

10-12 weeks (for complete Economiser, S panel etc.) 3-4 weeks

Creep , Thermal fatigue

18 months

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Issue: Inadequate Steaming Parameters

AREAS
Milling System Health of Pressure Parts Fan Margins System/ Process / Turbine demand

continue

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22

Issue: Inadequate Steaming Parameters

Reasons
Restricted mill capacity to handle the increased coal demand due to poor coal quality Poor health of Pr. Parts not permitting operation at the rated parameters / capacity Inadequate fan margins to cater increased coal demand Lower system demand Continue

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Issue: Inadequate Steaming Parameters

Remedies
Up gradation of Milling system Re- Design of Boiler / Replacement of Pr. Parts with improved design taking advantage of improved technology & materials Replacement of tangent / spaced tube construction with membrane panel Repair / Replacement / upgradation of Fans Arresting air ingress Addition of heating surface in equipment like economizer and APH continue
23 May 2012 PMI Revision 00 24

Issue: Low Efficiency

Areas
Improper design of boiler Milling System Burners Air Preheaters Furnace sealing

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Issue: Low Efficiency

Reasons
Improper heat pick up design resulting in high exit flue gas temperature Operational restrictions like metal temperature restrictions causing loss of Rankin efficiency Poor coal fineness due to milling system underperformance Improper mixing of air & fuel in burners resulting in carbon loss Poor performance of air preheaters resulting in high flue gas exit temperature (FGET) Air ingress into the furnace leading to high flue gas loss
23 May 2012 PMI Revision 00 26

Issue: Low Efficiency

Remedies
Redesign of boiler pressure parts based on TPT results: Addition / deletion of heat transfer surface in various pressure parts sections / APH Change in metallurgy to allow higher tube metal temperatures Upgradation of milling system Improved burner design Renovation of furnace sealing including penthouse Upgradation of Fans if Fans are underperforming

23 May 2012

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Issue: Increased Emission & SPM

AREAS & CAUSES
Poor coal quality Combustion Technology Burners and operating constraints on fans Fuel fineness Milling capacity & internals ESP Sizing constraints due to fuel quality Continue

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Issue: Increased Emission & SPM

REMEDIES
Installation of Low Nox Burners ESP Addition of new fields in ESP Increasing the height of existing fields Addition of parallel stream Installation of latest controllers like EPIC II Introduction of Bag filters ACHIEVEMENTS POST R&M Reduction in the Nox level Reduction in particulate matter
23 May 2012 PMI Revision 00 29

A Case Study: R&M & LEP - DPL, Durgapur

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R&M & LEP - DPL, Durgapur

DPL has 5 boilers (2 x 30 MW and 3 x 75MW) which are almost 30 years old. The boilers were unable to achieve the rated parameters, mainly due to the following reasons: Deteriorated coal quality (High ash & Moisture, Lower GCV). Improper combustion Ageing of boiler Pressure & non Pressure Parts.

23 May 2012

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DPL, Durgapur Major Objectives

Improvement in Boiler Efficiency Restoration of Rated Evaporation Restoration of Steaming parameters Arresting Air Ingress Reduction in downtime

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DPL, Durgapur Major Activities

Super heater - Improved Metallurgy to cater the upset conditions during operation. BB tubes - leading tubes diameter reduced and protective shield provided before and after cavity to reduce erosion. Economizer Additional loops added to reduce backend. Erosion protection shield provided. Tubular APH Ferrules at gas entry point to reduce erosion Changing of Staggered tubes to inline (U#1&2) FD fan reconditioned, ID fan replaced to get required margin. continue
23 May 2012 PMI Revision 00 33

DPL, Durgapur Major Activities

Milling System

U#1 & 2 mills replaced with mills & PA fans of units # 3&4 3 nos. New mills provided for U # 3 & 4 (One old mill retained)along with hot PA fans Reconditioning of suction mill of U#5 Mill loading reduced to 80% at Max. load to take care of burner heat input New Civil foundation and PF pipes for all units Wind Box New Wind Box of improved design provided for all units.
23 May 2012 PMI Revision 00 34

DPL, Durgapur Performance Post R&M

Performance of Boilers achieved during PG Test

Boiler # 1 Boiler # 3 Boiler # 5 Sl. Description Unit Guarante Achiev Guarante Achiev Guarante Achiev No. ed ed ed ed ed ed 1 Thermal Efficiency % 86.11 89.91 86.7 88.62 84.95 88.34 (Corrected) 2 Steam Generation TPH 124.9 137.06 253 270.34 258 259.46

23 May 2012

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THANK YOU

23 May 2012

PMI Revision 00

36

Summary Table
Out Liquid Mag side Dye Depo Fibre Ultra netic DiaVis Pene Repli Samp sit Optic Component sonic particle metre ual trant cation ling Anal inspec testing inspec and inspe ysis tion tion. thick ction ness 1 2 3 4 5 6 7 8 9 10 Drum (Steam) Yes Yes No Yes Yes No Yes Yes No Water drum Yes Yes No Yes Yes No Yes Yes No Low tempeYes No No Yes No No No Yes Yes rature header Attempertion header High temperature economiser tubes Low temperature economiser tubes Convection superheater coils Primary superheater coils Yes Yes No Yes Yes No No Yes Yes

Hard ness

Others

11 Yes Yes Yes Yes

12

Swell measure ment

Yes

No

No

No

No

Yes

No

Yes

No

No

Yes

No

No

No

No

Yes

No

Yes

No

No

Yes

No

No

No

No

Yes

Yes

Yes

No

Yes Nondestructive oxide thickness 37 inspection

Yes

No

No

No

No

Yes

No

Yes

No

Yes

23 May 2012

PMI Revision 00

Prefinal superheater coils Final superheater coils Reheater coils High temperature headers Final superheater header Reheater headers Main steam piping Platen superheater header Primary superheater headers Economiser header Auxilliaries Boiler bank tubes Waterwall Furnace waterwalls

Yes

No

No

No

No

Yes

No

Yes

No

Yes

Yes Yes Yes

No No Yes

No No No

No No Yes

No No Yes

Yes Yes No

No No No

Yes Yes Yes

No No Yes

Yes Yes Yes Swell measure ment Swell measure ment

Yes

Yes

No

Yes

Yes

No

No

Yes

Yes

Yes

Yes Yes Yes

Yes No Yes

No No No

Yes No Yes

Yes Yes Yes

No No No

No No No

Yes Yes Yes

Yes No No

Yes Yes Yes

Yes Yes Yes Yes Yes Yes

Yes No No No No No

No No No No No No

Yes Yes No No No No

Yes No No No No No

No No No No Yes Yes

No No No No No No

Yes Yes Yes Yes Yes Yes

Yes No No No No No

Yes Yes No No No No

23 May 2012

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500 MW BOILER - RESIDUAL LIFE ASSESSMENT - EXTENT & QUANTUM OF TESTS Sl. No. Component VE DC ME & H TM DPT MPI FMPI on two longitudinal and four circumferencial welds. MPI at (sat.steamraiser tube dia 127 mm stubs : 89nos.,safety valve -6, Down comer-6, Feed nozzle-3 & other tap off34) 144 welds UT / IOT On two longitudinal and four circumferencial welds, at all tap off stub joints/ Butt joints (sat.steam-raiser tube dia 127 mm stubs : 89nos.,safety valve -6, Down comer-6, Feed nozzle-3 & other tap off-34) 144 welds

Steam Drum

Visual Examinatio n

6 locations along the length

On two longitudinal and four circumferencial welds, at all 4 spots of tap off stub longitudinal seam joints weld & 4 spots of 6 locations (sat.steamcircumferencial along the length raiser tube dia seam welds - 8 127 mm stubs No. : 89nos.,safety valve -6, Down comer-6, Feed nozzle-3 & other tap off34) 8 locations 6 spots 144 welds At twenty locations attachment welds at burners, wind box, wall blowers at accessible locations

6 locations

Water wall

At burners, soot blowers, Visual bottom ash Examinatio hopper, Z panel n and goose neck area

at burners, soot blowers, bottom ash hopper, Z panel and goose neck area on 10 tube samples

at burners, soot blowers, bottom ash hopper, Z panel and goose neck area

At accessible locations -20 tubes

10 Samples

1000 spots

At 20 locations

Water wall hanger & Screen Tubes

Visual On all water One sample each on attachment At six locations Examinatio wall hanger and from hanger tube welds at along the length n screen tubes & screen tube random

236 tubes

2 samples

1416

spots

10 locations

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Water wall ring headers

Visual Examinatio n

3 locations along the length for each header

Total -4 Nos

on 8 on 8 10 locations circumferencial circumferencial along the length welds welds

on 8 circumferencial welds

12 locations

4 locations

10 locations

8 welds

8 welds

8 welds

Water wall outlet headers, steam cooled wall headers and riser tubes

On On circumferencial On circumferencial welds at WW circumferencial W.W outlet welds at WW Visual Hardsness on outlet -12, welds at WW 8, SCW outlet10 locations outlet -12, Examinatio 46spots,Replicas SCW outlet-9, outlet -12, SCW 6, Raiser tubesalong the length SCW outlet-9, n SCW -4, WW- 2. Raiser tube outlet-9, Raiser 20 Raiser tube 20, & Stubs & tube -20, Total 41 20, Total 41 lugs: 150 Total Nos. Nos. 191 Nos. Replica-6 spots Hardness-46 spots on two tube samples 2 Samples

34 locations Visual Examinatio n

10

191 welds on attachment welds at random 20 locations

41 welds

41 welds

Economiser assemblies

Econimiser inlet and outlet header

Visual Examinatio n

Eco inlet header - 3 , Eco outlet header - 3

Eco inlet header 2 , Eco outlet header - 2

Eco inlet header - 2, Eco outlet header - 2, Eco outlet tubes - 6

On On circumferencial circumferencial welds at Eco On welds at Eco inlet - 4, Eco circumferencial inlet - 4, Eco outlet -6, Eco welds at Eco outlet -6, Eco Header stubs inlet - 4, Eco Header stubs & gamma outlet -6, 100 Nos at plugs-100 Nos Random at Random 110 welds 110 welds 10 welds

6 locations

4 welds (min)

10 locations(min)

23 May 2012

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LTSH coils and terminal tubes

Visual Examinatio n

one tube on each coil -118 Nos

at two locations by sampling

on all on all coils attachment along the length welds near roof at six locations and crown 1416 Nos plate welds at Random 20% 25 crown plates of 6 tubes each On circumferencial welds at LTSH Circumferencia inlet -2, LTSH l welds at outlet -4 and LTSH inlet -2, gamma plugs. LTSH outlet-4 Stubs : 200nos. 206 welds 6 welds

Internal oxide scale measurement covering all coils and terminal tubes (Top & Bottom elevations) - 708 spots 708 spots

118 tubes (min)

2 samples

1416 spots (min)

LTSH inlet and Outlet header

Visual Examinatio n

6 locations along the length at LTSH outlet Header

LTSH inlet -2 ,LTSH Outlet -2

LTSH inlet -2, SCW inlet - 4

Circumferencial welds at LTSH inlet -2, LTSH outlet-4

6 locations

4 locations

6 locations

6 welds

10

LTSH Desuperheate r links

Visual Examinatio n

6 locations along the length

Replica-2Nos

Circ.weld:Desu Desuperheaterperheater8,spray tube - Circ.weld:Desupe 8,spray tube 6 locations 2, thermowells rheater-8,spray 2, thermowells along the length -6,100% on all tube -2, 6,100% on all liner bolt welds thermowells -6 liner bolt welds & gamma plug & gamma plug

6 locations

2 locations

6 locations

30 welds

30 welds

16 welds

11

Radiant roof header, Economiser and LTSH support headers

Radiant roof header-7,LTSH Radiant roof Radiant roof support headerRadiant roof Radiant roof 7,LTSH headers -2, 4,ECO support Radiant roof Visual headers -2, LTSH 4,LTSH support support LTSH support header-8, 7,LTSH support Examinatio support header header 4, Eco header/ Eco header -4, Eco Flourscent header 4, Eco n 2, Eco support support header - support header support header MPI on Eco support header -8 header - 2 8 -8 & Stubs : 8 support header 200nos. stub-1096 stub joints 14 locations 6 locations 16 lcoations 215 welds 1120 welds (min) 19 welds

23 May 2012

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Divisional superheater panels 12

Visual Examinatio n

On all panels444 Nos

by sampling -

on all the six panels- 888 Nos including bends at pent house

on DMW joints, roof seal band weld and crown plate welds at roof at Random 20%.

in penthouse at identified locations

1.Institu oxide scale measurements covering all panels 400 spots in penthouse& in furnace. 2. UT of girdling loops 12 No. for checking stress cracking 400 spots & UT of 12 girdling loop

444 tubes

2 samples

888 spots

50 butt welds,crown plates of two panels

444 bends

13

Platen superheater coils

Visual On all panels Examinatio 432 Nos n

by sampling-2 Nos

432 tubes

2 samples

on DMW welds, roof seal band on all tubes and welds, crown covering all plate welds at coils-864 Nos roof and attachment welds Random 20% 30 butt welds, 864 spots crown plates of 6 panels

Insitu oxides scale - 200 Nos, on 24 girdling loops for stress cracking and 6 binding loops

230 locations

14

A)On 200 stub A)On 200 stub jointsB)Circum jointsB)Circumf ferential weld A)Circumferential erential weld at 6 locations at Inlet header weld at Inlet Inlet header -6, along the 6, outlet header -6, outlet outlet headerPlaten length, header-10, header-10, SHDP Visual SH InletHeader - SH InletHeader - 10, SHDP to superheater including swell SHDP to to platen Examinatio 2,SH outlet 2,SH outlet platen inlet and measurements platen connection-5, n Header -4 Header -4 connection-5, outlet headers outlet header connection-5, Drains and vents Drains and 4, inlet header Drains and stub-4 and vents stub-4 2 vents stub-4 gamma plugs and gamma and gamma plugs plugs

6 spots

6 spots

6 spots

225 welds

225 welds

25 welds

23 May 2012

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15

Reheater Panels-Final Reheater,Half Reheater

Visual Examinatio n

Final RH -736, HalfRH- 184, covering all panels

by sampling-6 Nos. Hardness measurement on Final RH coils : 100 nos.

On 50 DMW joints, Final RH-1472, attachment Half RH- 1472 welds and covering all crown plate panels welding 20% at random 50 butt welds,crown plates of 10 panels of full & half RH

on girdling loops for stress cracking at random , Insitu oxide scale analysis 1400 points

920 tubes

6 samples and 100 hardness spots.

2944 spots

1400 locations

16

Divisional superheater headers and reheater headers ( inlet, intermediate and outlet headers)

Visual Examinatio n

Division Panel Division Panel inlet-12, DP inlet-12, DP Div.SH Inlet : 2 & outlet-12,Wall outlet-12,Wall Outlet : 2 RH inlet-2,RH RH inlet-2,RH RHInlet header-4 , Platen inletPlaten inletoutlet -4 14,RH outlet-4, 14,RH outlet-4, RH links-4 RH links-4

On circ. weld On circ. weld joints at SHDP joints at SHDP On circ. weld inlet -6, SHDP inlet -6, SHDP joints at SHDP outlet-8,Wall outlet-8,Wall inlet -6, SHDP RH inlet-4,RH RH inlet-4,RH outlet-8,Wall RH Platen inletPlaten inletinlet-4,RH Platen 12,RH outlet12,RH outletinlet-14,RH outlet10 and 400 10 and 400 12 nipple welds & nipple welds & gamma plugs gamma plugs

36 spots

12 spots

36 spots

40 butt welds 40 butt welds and 400 nipple and 400 nipple welds welds

44 butt welds

17

Visual Boiler integral Examinatio piping (carbon n steel) and down comer

Minimum one on each integral piping

Replica-2 Nos

Minimum one At At At circumferential on each integral circumferential circumferential welds piping welds welds

12 locations

2 spots At SH connecting link-2 Nos, MS piping from boiler to stop valve4Nos 6 spots

12 spots

12 welds MS-4, Thermowell stub-4, safety valve / ERV stub -14 22 welds

12 welds MS-4, Thermowell stub-4, safety valve / ERV stub -14 22 welds

12 welds MS-4, Thermowell stub4, safety valve / ERV stub -14 22 welds

18

Visual Boiler integral Examinatio piping(alloy n steel including MS upto stop valve)

MS -4 Nos

MS -4Nos

4 locations

4 spots

23 May 2012

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19

Main Steam, Hot reheat MS-6,HRHand cold 14,CRH-5,Feed reheat piping water-2 Visual At three spots on downcomers, ,Suction Examinatio each piping -18 feedwater manifold-3, CC n Nos piping, CC pump pump suction discharge-6 manifold & ,Eco links- 6 discharge piping, 42 locations 18 spots Economiser Boiler Expansion Visual Examinatio n

MS-6,HRHMS-6,HRHMS-6,HRH14,CRH-5,Feed 14,CRHMS-6,HRH14,CRH-5,Feed water-2 5,Feed water-2 14,CRH-5,Feed water-2 ,Suction ,Suction water-2 ,Suction ,Suction manifold-3, CC manifold-3, CC manifold-3, CC manifold-3, CC pump pump pump dischargepump dischargedischarge-6 discharge-6 6 ,Eco links- 6 6 ,Eco links- 6 ,Eco links- 6 ,Eco links- 6 42 spots 42 welds 42 welds 42 welds

20

LEGEND VISUAL EXAMINATION DIMENSIONAL CHECKS VE DC

METALLOGRAPHIC EXAMINATION & ME&H THICKNESS MEASUREMENT TM DYE-PENETRANT TESTING DPT MAGENETIC PARTICLE INSPECTION MPI WET FLOURSCENT MAGNETIC FMPI PARTICLE INSPECTION ULTRASONIC TESTING UT RADIOGRPAHIC TESTING RT FIBRO SCOPE TESTING FB DEPOSIT ANALYSIS 23 May 2012 PMI RevisionDA 00

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THANK YOU

23 May 2012

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