Repair Procedure for F- 23202 WORK FLOW & SKETCH

1. Before start work, the new plate shall be performing Positive Material Identification (PMI), lamination check and ultrasonically tested to ensure the plate meet the standard requirement. 2. Weldability test for old plate to new plate shall be performed before proceeding for actual job. 3. Identify and mark the areas of header box pipe for replace damage plate (bulge).

4. Clean up the surfaces (pipe surface) by power brushing (or wire brushing for areas nonaccessed by power tool). All rusts and scales shall be removed. 5. To perform Ultrasonic Thickness Measurement (UTTM) and Lamination check at welding areas at the header (marked by PPMSB) 6. All spring hangers shall be lock before start work. Prepare support to limit the pipe movement. The support should have tolerance maximum 10mm. 7. Roll new plate using the cut piece as a template. 8. After completed cleaning, precede cutting and remove the damage area on header box pipe using oxy cutter. Tack weld spring hanger patch plate on new plate and proceed grinding to prepare joint preparation (beveling).

9. Magnetic Particle Test (MPT) shall be performing once completion of surface preparation to detect any sign of defects.

10. Before start welding, precede Hydrogen Bake Out process (dehydrogenations) for 2 hours in temperature range 300C to 400C for old plate and ensure preheat temperature above 177C as per required for new plate.

11. Follow the sequence of welding and welding repair process shall be strictly complying accordingly with the following documents which are relevant and approved by an authorized party.

12. Liaise with AIM personnel to inspect fit up as per joint design. Jig shall be installing to ensure proper fit up and control against plate deformation. 13. After complete the first root and hot pass of welding, perform Magnetic Particle Test (MPT) and Ultrasonic Flaw Detection (UTFD). Proceed welding if MPT and UTFD result acceptable.

14. Any stoppage or interruption of welding, to be bake at 350C for 2 hours using heating element to avoid hydrogen delayed cracking. 15. Completed weld to be visual inspected and NDT (MPT and PAUT). 16. Repeat steps 7 to steps 15 for re weld pipe to pipe, joint no.5.

17. To install spring hanger pad, perform hydrogen bake out on the spring hanger support at 350C for 2 hours and preheat new plate as per WPS attached. 18. Once complete, precede fillet weld. Completed weld to be visual inspected and MPT & PAUT.

19. Post Weld Heat Treatment (PWHT) shall be performing after completed welding. The holding time (1 hour) and temperature range (700C to 750C) as per PWHT procedure attached. 20. After complete PWHT, carry out MPT, Phase Array Ultrasonic Testing (PAUT) and Hardness Test (225Hb Max.)