SAUDI ELECTRICITY COMPANY

REPLACEMENT OF 3RY-SH & FURNACE BOTTOM

WATER PANELS FOR STAGE-III
(STEAM UNITS NO≠ 6) AT RABIGH PP.

PROCEDURE FOR:

INSTALLATION OF PARTIALLY 3RY-SH & FURNACE

BOTTOM WATER PANELS

SEPTEMBER 2018

COUNTRY HOUSE FOR CONTACTING & OPERATION.

Prepared by: Marwen Lasmar / Hamoudi Moez./ Med Hedi Zemzem

BOILER #6-SEC-RPP TECHNICAL REPORT

Contents:
Description
PURPOSE
I. BOILER SPECIFICATION:
II. OUTLINE OF MODIFICATION WORK: II
III.PREPARATION:
IV.3RY-SH:
A. Removal the old Partially of 3RY-SH Tubes/Coils .
B. Installation the new Partially of 3RY-SH Tubes/Coils
V.BOTTOM TUBES (REAR & FRONT) & SIDE WALL TUBES (RIGHT & LEFT)
A. Removal Bottom Tubes (Rear & Front) & Side Wall Tubes (Right & Left)
B. Installation of the Bottom Tubes (Rear & Front) & Side Wall Tubes (Right & Left
VI. HYDRAULIC TEST:
VII.CHEMICAL CLEANING:
A. Pressure Testing of Temporary Equipment:
B. Initial Copper Removal Stage:
C. Water Flushing:
D. Hydrochloric Acid Cleaning Stage:
E. Water Flushing & Rinsing :
F. Citric Acid Rinse Stage
G. Passivation Stage:
VIII.INSULATION WORK:
IX.ATTACHMENTS:

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Purpose;
the purpose of this procedure is to provide a preliminary reference guideline
for removal and installation for partially replacement of SRY-SH Furnace &
Bottom Water Panels for Stage-III Steam Units Nos. 5&6 at Rabigh Power
Plant. ADDAR bears no responsibility in case of any changes, alteration and
/or modification of the procedure as required during actual execution

for more details and confirmation of the specification, site inspection shall be
carried out by the prime bidder and the agency for the modification work.

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I. BOILER SPECIFICATION:

1. BOILER TYPE: Mitsubishi forced circulation radiant reheat boiler (MB-FRR)

a. Capacity: 832 T / Hr.
b. Working pressure, max.: 175.7 Bar
c. No. of down comers:6
d. No. of BCPs: 3 sets / unit
e. Pump Capacity : 3880 cu.m / hr (Each Pump)

2. STEAM DRUM:
a. Number :1
b. Inside Diameter :1.662.5mm
c. Length (of shell and tube plate):12.900mm

3. FURNACE:
a. Type: welded wall water cooled, joint type
b. Furnace width:10.608 mm
c. Furnace depth: 8,925 mm
d. Furnace height:27,070mm
e. Furnace volume:2,380 m3
f. Total heating Surface:2,130m3

4. SUPERHEATER:
a. Bank type:
Roof and secondary pass: Steam cooled wall type
Wall superheater: Horizontal platen radiant and hanger tube type.
Secondary super heater: Horizontal platen radiant type
Tertiary superheater: Horizontal spaced convective type.
b. Heating surface:
Steam cooled wall :590m3
Primary super heater :460m3
Secondary Super heater:1,250 m3
Tertiary super heater:2,100m

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II. OUTLINE OF MODIFICATION WORK:

The scope of modification is to:

- Partially Replacement of 3RY-SH Tubes/Coils (Total 68 Coils and each Coil consists
of 6 tubes of dimension 48.6 mm * 10.2 and 42.7 mm) super heater-outlet header
3RY-SH, which are of upgraded design from the existing ones.

To make access for removal and installation, one opening-A01 will be made in the
water wall at level of 3RY-SH (FL+32900) with dimension 90*1100 mm, in the right
side of the water wall. The Partially of 3RY-SH Tubes/Coils element will be
dismantled in blocks and will be taken out in outside the water wall of the boiler.

To provide access for removal of tubes coils super heater 3RY-SH. The Skin Casing,
Refractory cladding & outer casing around 3R-SH SH Headers need to be removed
from their places.

To provide access for removal of the lower panels (Rear & Front), Side Wall panels
(Right & Left) and Stab Tubes. the cladding, outer casing & Skin Casing of the Water
Drum, cladding and Cement refractory of bottom furnace.

- Replacement of lower panels (Rear & Front), Side Wall panels (Right & Left) and
Stab Tubes which are of upgraded design from the existing ones.

-There will be a requirement of installation and dismantling of temporary material

/support, permanent material and support during the modification process.

-Perform Step by step installation of new panels according to the assembly drawings.

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III. PREPARATION:

1. Keep all necessary drawings (assembly drawing, sectional drawing, part details.…) and
document (procedures, execution plan etc..) with latest revision ready, prior to start of
work.

2. Prepare the necessary handling facilities (lifting equipment, hoist, forklift, crane and
support, etc. to removed and store the various spare parts of equipment’s).

3. Coordinate with the electrical, mechanical and I&C department if necessary to remove
any component (switch pressure, pressure transmitter, soot blower’s burners,
thermocouple, etc..) before starting disassembly work.

4. Tool list and consumable list shall be made and be arranged to avoid any delay.

5. Make the works’ procedure and the schedule based on the estimate beforehand.
(Attachment)

6. Arrange the workmen in required groups for rehabilitation work. Make a group structure
for mobilization.

7. The scaffolding in the around lower panels and super heater 3RY-SH shall be planned
and necessary step shall be calculated and arranged.
For the use of electrical equipment for heating and welding illumination, calculate
temporary electrical capacity and decide a temporary electrical source of supply. In
case shortfall, diesel generator shall be arranged.

8. Opening the manholes /Access door opening in different side of the furnace and super
heater.
Precaution:
 Obtain necessary work permits before start of any work. Ensure electrical
supply to the actuators is disconnected. The circuit breaker is locked and
tagged.
 The FD fan should be electrical isolated. the breaker must be racked out
locked and Tagged

 Note: -All data is to recorded during headers and tubes inspection

and removal.

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IV. 3RY-SH: (Attachment 4) . (Attachment 6) . (Attachment 7)

A. Removal the old Partially of 3RY-SH Tubes/Coils .

1. Install Necessary Scaffolding & Lighting inside the furnace between at level FL+32900.
ovens to protect workers from accident during the work of bottom furnace.

2. Install Necessary Scaffolding outside around from different side of the water wall at level
FL+32900.(Attachment 1).

 Caution: Access to passing people is necessary with proper

scaffolding and walkways

3. Marking and remove insulation, skin casing around the marked location of panels A01
from right side of the water wall respectively at level FL+32900 (Attachment 1)

4. Marking & Cut the opening of water wall arch screen tubes panels (A01) at level
FL+32900 according the drawing, and Put cap on the opening at the cutting location to
prevent ingress of dust and debris inside the tube. (Attachment 3)
 Caution: Care should be taken to avoid damage to the adjacent tubes
in the panel during cutting operation.

5. Remove the Calcium Silicate Board, Refractory Castable skin casing, around outlet header
3Ry-SH.

6. Mark the location of outlet header SH-3RY & outlet pipe for cutting and Cut the welding
joints between outlet pipe 3RY-SH and tube coils 3RY-SH at upstream location shall be
done through grinding.

7. Cover the opening properly to prevent ingress of dust and debris.

 Caution: Care should be taken to avoid damage to the adjacent tubes

during cutting operation and according with drawing.

8. Shift the old coils one by one towards manhole at level FL+32900 and carry out by
crane to area scrap.

B .Installation the new Partially of 3RY-SH Tubes/Coils

1. Beveling and cleaning the New Coils (3RY-SH), & the connection ends (of removal
coils tube).

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2. Lift the coils 3RY-SH carefully through the opening in the deflection arch.

3. Orient the blocks properly for further through the opening in the rear wall
deflection arch panel.

4. Align and fit up coils/ tubes (3RY-SH) with the connection ends one by one
according the drawing.

5. Heating (T=150⁰) & Welding (1224 Joints) between the New coils (3RY-SH) & the
connection ends ((Furnace Middle Side)- (D3.D4),(Furnace Rear Side)- (D8) and
(Front Outlet Hdr. Side) (D2))

ITEM DESCRIPTION Nb of Material Dia Thick PREHEAT RT PT HEAT

Joint (mm) (mm) (min.⁰C) TRETEMENT
D2 3RY SH TUBE 408 SA213-T22 48.6 10.2 150 X
(Front Outlet Had.
Side)
D3 3RY SH Tube 204 SA213M- T22 42.7 8.7 150 X
(Furnace Middle
Side)
D4 3RY SH Tube 204 SA213M- T91 42.1 5.3 150 X X
(Furnace Middle
Side)
D8 3RY SH Tube 408 SA213M- 42.7 5.3 150 X
(Furnace Rear Side) TP347HFG
D5-a Support Plate 1088 SA213M- 150 X
Hanger Tubes TP347HFG

6. Tag weld and weld the Support Plat of hanger tubes 3RY-SH

 Note: There will be a requirement control with NDT to be carried out as per
ASME code during the modification process.

7. Preformed 100% Radiographic Test (RT) for welded joints of New coils (3RY-SH)
and hanger tubes.

 Not: Do the necessary repair according to Radiographic Test (RT).

8. Preform 100% Heat treatment for welded 3RY SH Tube (Furnace Middle Side) (D-
4),

9. Re-install skin casing of SH Headers:

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V. BOTTOM TUBES (REAR & FRONT) & SIDE WALL TUBES (RIGHT &
LEFT) Attachment 8, Attachment 9, Attachment 10, Attachment 11, Attachment 12,
Attachment 13,Attachment 14, Attachment 15, Attachment 16

A . Removal Bottom Tubes (Rear & Front) & Side Wall Tubes (Right & Left)

1. Install Necessary Scaffolding inside/outside around the Furnace

2. Removal of cladding, outer casing & skin casing of the front and rear Bottom panels,
Side Wall Panels including Cement and Calcium Silicate Board of Water Drum.

Tracing and marking the requested panels to be removed from Bottom Tubes (Rear & Front)
& Side Wall Tubes (Right & Left) according with drawing

3. Preparation and install temporary support of water drum.

There will be a requirement of installation and dismantling of temporary material
/support, permanent material and support during the modification process.

 Note: There will be a requirement control with NDT to be carried out as per
ASME code during the modification process.
4. -Installation of lifting equipment from bottom (Rear & Front) & side wall tube
(Right & Left)

5. Cut and removal of Right and Left Tubes Panels at upstream location shall be done
through grinding and Cover the connection ends tubes to prevent ingress of dust
and debris

 Caution: Care should be taken to avoid damage to the adjacent tubes

during cutting operation and according with drawing.

6. Cut of furnace Bottom Tubes & Side wall Tubes and New Nozzles of Water Drum
upstream location shall be done through grinding and Cover the connection ends
tubes to prevent ingress of dust and debris

7. Removed the hangers lug from Front and Rear water wall bottom panel.

8. Removed the fitting plates & corner seal plates for front and rear wall lower panel

9. Cut of Stub Tubes of Water Drum upstream location shall be done through grinding
and Cover the connection ends tubes to prevent ingress of dust and debris

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 Caution: Cover the connection ends tubes to prevent ingress of dust and
debris and take care to avoid damage to the adjacent tubes during
cutting operation and according with drawing.

B . Installation of the Bottom Tubes (Rear & Front) & Side Wall Tubes (Right &
Left ( Attachment 8, Attachment 9, Attachment 10, Attachment 11, Attachment 12,
Attachment 13, Attachment 14, Attachment 15, Attachment 16)

1. Adjusting and Beveling the connection ends (of removal panels). Front /rear
furnace, Side wall Tubes and existing tubes nozzle of water drum.

Caution: Care should be taken to avoid damage to the adjacent tubes

during cutting operation and according with drawing.
2. Adjusting and Beveling the new panels and stub tubes to be install.

3. Lift, Align and fit up of panels to be install and Perform Step by step installation
according to the assembly drawings.

4. Heating (T=150⁰c), & Welding of new panels with the connection ends.

ITEM PARTS MATERIA DIA(MM) THICK(MM) NO.OF PRHEAT

L JOINTS
FRONT& REAR WALL TUBE NOZZEL SA210-C 38.1 4.6 150
D9 (STUB) 414
FRONT& REAR WALL TUBE SA213M- 38.1 4.6 150
T12
D10 FRONT &REAR WALL LOWER TUBES SA213M- 38.1 4.6 150
T12 414
FRONT &REAR WALL LOWER TUBES SA213M- 38.1 4.6 150
T12
FRONT &REAR MIDDLE TUBE(EXISTING) SA213M- 38.1 4.6 150
D4 T12 414
FRONT &REAR MIDDLE TUBE(EXISTING) SA213M- 38.1 4.6 150
T12
FURNACE SIDE WALL TUBES (EXISTING) SA213M- 38.1 4.6 150
D1 T12 352
SIDE WALL LOWER PANEL SA213M- 38.1 4.6 150
T12
D1 SIDE WALL LOWER PANEL SA213M- 38.1 4.6 150
T12 40
SIDE WALL LOWER PANEL SA210-A1 38.1 4.6 150
SIDE WALL LOWER PANEL SA213M- 45 6.4 150
D3 T12 156
SIDE WALL LOWER PANEL SA210-A1 45 4.9 150
Total of 1790
Joints

5. Preformed 100% Radiographic Test (RT) for welded joints

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 Not: Do the necessary repair according to Radiographic Test (RT).

6. Heating (T=150⁰c), & Welding of stab tubes with the connection ends one by one
according to the assembly drawings.

VI. CARRYOUT HYDRAULIC TEST OF THE BOILER ISLAND AS PER

PROCEDURE.

 Note: All necessary precautions need to be taken before, during and after
the hydraulic test.

VII. CHEMICAL CLEANING: (Attachment 3:,Attachment 16:)

-It is necessary to chemically clean a boiler periodically for its efficient operation,
corrosion control and prevention of tube failures. The prime objective of chemical
cleaning is to assist process facilities in achieving their designed and desired levels of
production efficiency as soon as possible after startup of the facility. The removal of
metal oxides (Fe), followed by inhibition of rusting subsequent to cleaning describes to
scope of chemical cleaning for carbon steel items in general. It must be emphasized that
good chemical cleaning results can only be achieved if the chemicals employed are able
to function unimpeded. The end product will be bare metal with a grey to dark grey
passivation coating and the absence of any visible iron oxides.
-The selected chemical cleaning method will normally involve the following steps in the
following sequence:
1) Iron Removal (by inhibited Hydrochloric acid)

2) Citric Acid Rinse

3) Passivation.

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H. Pressure Testing of Temporary Equipment:

1. Erect pumps, tanks and pipework, effluent storage etc. as per latest schematic
circuit diagram.

2. Fill system with water and pressure test temporary pipework; to pump discharge
pressure.
3. Commission Superheater Back Flushing Pump and continue until positive rise in
drum level is indicated.
I. Initial Copper Removal Stage:
4. Commission Circulation pump and commence circulation. Start Boiler Circulation
pump. Note drum level and adjust accordingly.

5. Heat up until water temperature of 55 –60°C is achieved.

6. Lower drum level to accommodate cleaning chemicals.
7. Commission chemical\mixing station and inject chemicals to give the following
concentrations:
pH 9-10 Ammonia{25%Conc.}
0.5% w/w Ammonium Bicarbonate
0.5% w/w Sodium Nitrite

8. Circulate for 6 hours or until constant Copper concentration is achieved.

Alternate boiler circulation pumps for 10 minutes every hour.
9. Drain the Circulated water under Nitrogen to the disposal tank and Refill the
system with BFW and Rinse.
J. Water Flushing:
10. Refill the system with BFW & Circulate for 30 Min.
11. Drain the Circulated water to the disposal tank and Refill the system with BFW
and Rinse if required.
12. Flushing / Rinse Shall be Stopped when pH of BFW is equal to Flushing water.
K. Hydrochloric Acid Cleaning Stage:
13. Commission pump and commence circulation. Note drum level and adjust
accordingly.
14. Backflush superheater until positive drum level rise is observed.

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15. Lower drum level to accommodate cleaning chemicals.

16. Heat up until water temperature of 50 –60°C is achieved.
17. Commission chemical\mixing station and inject chemicals to give the following
concentrations:

5-6% w/w HCL Acid{33%conc}

0.25% w/w Armohib 28

0.5% w/w Ammonium Bifluoride

1. Circulate for 6 hour or until acceptable chemical concentrations are achieved.

2. Stop economizer and boiler circulation pumps. Drain boiler & economizer
under nitrogen to effluent storage.
3. Briefly flush to open drains for 10 minutes to enable all acid solution to be
removed from boiler and circulation piping.
L. Water Flushing & Rinsing :
1. Refill the system with BFW & Circulate for 30 Min.
2. Drain the Circulated water under Nitrogen to the disposal tank and Refill the
system with BFW and Rinse.
3. Rinse Shall be Stopped when pH >5 and Iron content is < 50ppm.
M. Citric Acid Rinse Stage:
1. Refill system with water to cleaning level. Start pump and commence circulation.
2. Heat Up the Circulating water 40* C to 50* C and Proceed for Commissioning of
Citric Acid.
3. Commission chemical\mixing station and inject chemicals to give the following
concentrations: -

0.2% w/w Citric Acid

Ammonium to pH 3.5 – 4

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1. Circulate for 1 hour of Temperature 40⁰ C to 60⁰ C.

2. Stop economizer and boiler circulation pumps. Drain boiler & economizer to
evaporation pond. Backflush superheater for 10 minutes.
3. On Completion of Citric Acid Draining Proceed to Next Stage for Passivation.
N. Passivation Stage:
1. Commission Economizer Circulation pump and commence circulation.

Note: drum level and adjust accordingly.

2. Backflush superheater until positive drum level rise is observed.

3. Heat Up the Circulating water 40* C to 50* C and Proceed for Commissioning of
Passivation Chemical.
4. Commission chemical\mixing station and inject chemicals to give the following
concentrations:
1% to 2% w/w Citric Acid
Ammonium to pH 9 – 10
0.6 % w/w Sodium Nitrite

5. Circulate for 4 - 6 hours. Alternate boiler circulation pumps.

6. Commission chemical\mixing station and inject chemicals to give the following
concentrations:
7. Remove temporary steam / Water drum door and Install Air remover for
Ventilation.
8. Inspect the Steam / Water drum interior surface for Final Inspection.
9. Box up the Permanent Man doors of Steam / Water drum and dismantle all the
temporary hose connection to hand over the boiler to RPP .
VIII. INSULATION WORK:
After satisfactory completion of hydraulic test and chemical cleaning:
1. Refill all the cement refractory of skin casing of water drum, skin casing of SH-Header
including the manholes Bottom furnace.
2. Reinstall the Rock Wall and cladding around bottom furnace of the water wall
3. Remove all platform scaffoldings and Cleanup the Area for final Inspection.

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IX. ATTACHMENTS:
-Attachment 0: Construction Work Schedule for Unit # 5
-Attachment 1: Temporary scaffolding between the 3RY-SH and bottom furnace for
protect the worker bottom furnace
-Attachment 2: Insulation & Chemical Schedule (Unit #.5)

-Attachment 3: Detail of Opening in the screen tubes panels location A01

-Attachment 4: Arrangement of pressure part

-Attachment 5: Additional Works for Furnace Right & left Side Wall Panel Boiler Unit # 5
-Attachment 6: Assembly of 3RY-SH panel

-Attachment 7: Front housing support

-Attachment 8: Assembly &detail of front & rear wall lower panel

-Attachment 9: Detail of corner seal plate for front & rear wall lower panel
-Attachment 10: Arrangement of front & rear wall lower panel
-Attachment 11: Assembly &detail of front & rear wall lower panel
-Attachment 12: Arrangement &Detail of corner seal plate for front & rear
-Attachment 13: Arrangement of right & left side wall lower panel
-Attachment 14: Assembly & detail of right & left wall lower panel
-Attachment 15: Detail of side wall panel
-Attachment 16: Arrangement &Detail of attachment of lower panel

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