Prepared By: Khurram Fayyaz Inspection Report during Plant Outage @ NA Plant Equipment: B-101 A/H-105 A (Lamont Boiler) Inspection Technique: VI, DPT, UT and Metallography INSPECTION SCOPE: • VI and DPT of Burner Head. • DPT of Weld Seams of Shroud. • DPT of Welding Seams of Catalyst Basket. • Hardness Measurement. • Visual Inspection of Coils. • Thickness Monitoring of Coils. • Inspection of Shell, Nozzles and coils welding joints. • Metallography of Shell OBSERVATIONS: Inspection of B-101 A/H-105 A (Lamont Boiler) was carried out and observations are as follows:- • DPT of Welding Seams of Burner head was carried out and no cracks/pinholes were observed • DPT of Welding seams of Catalyst basket was carried out and found satisfactory • DPT of Burner head external and internal nozzles was carried out and found satisfactory • DPT of Weld Seams of Shroud was carried out and found satisfactory • Mesh of Basket found damaged at one point. New Mesh Installed. • Thickness Monitoring of coils was carried out; Max: 3.7 mm, Min: 3.4 mm, Design: 3.6 mm • Hardness Testing of shell was carried out and all the values are in acceptable range; Max: 175 HB, Min: 150 HB Hardness Values in TA-2015: Max: 190 HB, Min: 135 HB • 70% Thickness monitoring of line included fittings from H-105 to H-112 has been carried out and found satisfactory. • Max: 6.7 mm, Min: 6.1 mm, Design: 4.2 mm • Metallography activity for La-Mont Boiler on H-105 A/B has been completed, 01 Replica from H-105 A on shell was taken. Report is awaited.
Transcript
Prepared By: Khurram Fayyaz
Inspection Report during Plant Outage @ NA Plant Equipment: B-101 A/H-105 A (Lamont Boiler) Inspection Technique: VI, DPT, UT and Metallography INSPECTION SCOPE:
• VI and DPT of Burner Head. • DPT of Weld Seams of Shroud. • DPT of Welding Seams of Catalyst Basket. • Hardness Measurement. • Visual Inspection of Coils. • Thickness Monitoring of Coils. • Inspection of Shell, Nozzles and coils welding joints. • Metallography of Shell
OBSERVATIONS: Inspection of B-101 A/H-105 A (Lamont Boiler) was carried out and observations are as follows:-
• DPT of Welding Seams of Burner head was carried out and no cracks/pinholes were observed • DPT of Welding seams of Catalyst basket was carried out and found satisfactory • DPT of Burner head external and internal nozzles was carried out and found satisfactory • DPT of Weld Seams of Shroud was carried out and found satisfactory • Mesh of Basket found damaged at one point. New Mesh Installed. • Thickness Monitoring of coils was carried out;
Max: 3.7 mm, Min: 3.4 mm, Design: 3.6 mm • Hardness Testing of shell was carried out and all the values are in acceptable range;
• 70% Thickness monitoring of line included fittings from H-105 to H-112 has been carried out and found satisfactory.
• Max: 6.7 mm, Min: 6.1 mm, Design: 4.2 mm • Metallography activity for La-Mont Boiler on H-105 A/B has been completed, 01 Replica from H-105 A on shell
was taken. Report is awaited.
Prepared By: Khurram Fayyaz
Inspection Report during Plant Outage @ NA Plant
PICTORIAL
DPT of nozzle of Burner head
DPT of T-Joints of basket
Prepared By: Khurram Fayyaz
Inspection Report during Plant Outage @ NA Plant PICTORIAL
Mesh of basket found damaged
Thickness Monitoring of Coils
Prepared By: Khurram Fayyaz
Inspection Report during Plant Outage @ NA Plant
Equipment: B-101 A/H-105 B (Lamont Boiler) Inspection Technique: VI, DPT, UT and Metallography INSPECTION SCOPE:
• VI and DPT of Burner Head. • DPT of Weld Seams of Shroud. • DPT of Welding Seams of Catalyst Basket. • Hardness Measurement. • Visual Inspection of Coils. • Thickness Monitoring of Coils. • Inspection of Shell, Nozzles and coils welding joints. • Metallography of Shell
OBSERVATIONS: Inspection of B-101 A/H-105 B (Lamont Boiler) was carried out and observations are as follows:-
• DPT of Welding Seams of Burner head was carried out and no cracks/pinholes were observed • DPT of Welding seams of Catalyst basket was carried out and found satisfactory • DPT of Burner head external and internal nozzles was carried out and found satisfactory • DPT of Weld Seams of Shroud was carried out and found satisfactory • Mesh of Basket found satisfactory. • Thickness Monitoring of coils was carried out;
Max: 3.8 mm, Min: 3.4 mm Design: 3.6 mm • Hardness Testing of shell was carried out and all the values are in acceptable range;
• 70% Thickness monitoring of line included fittings from H-105 to H-112 has been carried out and found satisfactory. Max: 6.4 mm, Min: 5.9 mm, Design: 4.2 mm
• Metallography activity for La-Mont Boiler on H-105 A/B has been completed, 03 Replicas from H-105 B were taken (02 Replica from Shell near Cracks & 01 Replica from Flanged Portion near Crack). Reports are awaited.
• The existing crack has been checked and measured by Inspection team and No increase in crack size (Length) observed.
Prepared By: Khurram Fayyaz
Inspection Report during Plant Outage @ NA Plant
PICTORIAL
DPT of T-Joints of Basket
DPT of T-Joints of burner head
Prepared By: Khurram Fayyaz
Inspection Report during Plant Outage @ NA Plant
PICTORIAL
DPT of nozzle of Burner head
DPT of Crack on shell after placing burner head back
Prepared By: Khurram Fayyaz
Inspection Report during Plant Outage @ NA Plant
Equipment: CDM NH3 Evaporator line Inspection Technique: VI, DPT, UT INSPECTION SCOPE:
• VI and DPT of Line • UT of Line
OBSERVATIONS: Inspection of CDM NH3 Evaporator line was carried out and observations are as follows:-
• Thickness Monitoring of CDM NH3 Evaporator was carried out and found satisfactory Design: 5.54 mm, Min: 5.5 mm, Max: 5.7 mm
• DPT of complete line was carried out. 01 location through hole crack observed approximately 08 to 10 mm length. Needs to be repair.
Work Done:
• After grinding DPT was performed again and branches of cracks were found due to which CDM ammonia vaporizer affected portion has been replaced with a new one.
• DPT after Welding activity was carried out by Inspection and results found satisfactory.
Crack view after DPT
Prepared By: Khurram Fayyaz
Inspection Report during Plant Outage @ NA Plant
Miscellaneous Jobs:
1. Internal Inspection of Filter L-101 Air Duct was carried out. o Cleaning required before Box-Up. o Overall condition found satisfactory.
2. DPT after welding of STG Joints was carried out and found satisfactory. 3. PWHT of 09 Joints of STG area was carried out. Job Completed. 4. RT of 09 Joints of STG area has been carried out in night shift. Result found satisfactory.
