ANNUAL OUTAGE REPORT BY Syed Fahim Kazmi

and Ali Dost

The following report is an overview of the activities we witnessed and

learned in the Uch 2 outage 2015.

HRSG
-

On day one we got the work permit to open the manholes and gates of
the HRSG compartments to let it cool down for a day or two.

This is because in inside temperature of the boiler is very high, so a

cooldown time is required for safe inspection and maintenance.

After opening and cooling of the manholes, The inside of the HRSG was
inspected for any hotspots and insulation damage.

A few hotspot locations we identified by the inspection teams and were

welded and glass wool insulation was refilled for better operation.

Scaffolding was installed to reach the upper joints where hotspots were
detected. Carbon steel plates were installed and welded at these
locations.
Furthermore, Non destructive testing of the welds was done with the
help of Dye Penetrant testing and Magnetic Particle Inspection to make
sure there are no cracks, pinholes of damage to the welded portion.

After the HRSG manholes were opened and cooled for about two days,
We started NDT of the pipes installed at the bottom of the HRSG.

Limestone was placed inside these confined spaces to absorb any

moisture in this compartment. Furthermore, there are 4 inch and 8inch
diameter pipes located within the right and left gates of this
compartment. DPT and MPI of the welds of these pipes were done by
the third party to find any cracks, pinholes or any damage which could
result in leakage of the pipes.

After the boiler drums, HP, IP and Feedwater drums were opened and
cooled, they were thoroughly inspected visually for any damage.
Furthermore, DPT and MPI were done to find any cracks, pinholes or
any damage on the welded joints.

IP compartment of the drum from the inside.

HP compartment of the drum from the inside.

There was a crack and a missing piece found inside the surface of the
Feedwater drum. Due to the darkness inside the drum, no picture could
be taken. That crack has now been repaired by installing a carbon
steel sheet and welding it to the sides. Furthermore, DNT was
performed by third party to ensure there are no cracks, pinholes or any
damage on the welded joints.

Inspectest engineer performing DPT inside the feedwater drum.

NDT was performed on IBT and CBT tanks. Before this, they were
thoroughly cleaned with the help of a grinded since the inside surface
gets corroded due to the chemicals and high temperature.

A crack was found of 5mm inside the surface of IBT of HRSG 2. It has
been claimed but is yet to be repaired. Furthermore, a transmitted was
removed and installed at a lower location on the IBT.
A 13mm crack was found inside the surface of CBT. It is yet to be
repaired.