UIP JBB

UPP PJBB1

No : /KON.01.02/400400/2020 September 11th, 2020

Attachment : 1 (one) set
Priority : -
Subject : Lead Pipe and OLV Pipe Issue 5th To:

Project Manager
Consortium SC – BVI - SSP

Refers to:
1. Contract Documents No. 0436.PJ/DAN.02.01/DIR/2015 Lontar Extension Coal Fired
Steam Power Plant (1x315MW) Book III A, Sub-Section 4.6.1.1.2 Steel Piping System.
2. Contract Documents No. 0436.PJ/DAN.02.01/DIR/2015 Lontar Extension Coal Fired
Steam Power Plant (1x315MW) Book III A, Sub-Section 4.6.2.7 Main Steam Piping.
3. PLN Letter No. 0173/KIT.02.01/B40040000/2020 Dated 10 th August 2020 Regarding
P91 Piping Repair Plan and Schedule (Crack Type IV).
4. PLN Letter No. 0091/KIT.02.01/B40040000/2020 Dated 20 th May 2020 Regarding
Excessive Welding Root on Internal Main Steam Pipe and OLV Pipe.
5. Site Transmittal Document No. 0227/400400/2020 Dated 29th July 2020 Regarding P91
Piping Repair and Schedule.
6. Consortium Letter No. L-SC-BV-SSP-PLN-30286 Dated 17 th July 2020 Regarding P91
Piping Repair and Schedule.
7. Site transmittal No. CONS-PLN-6114 Dated 24 th August 2020 Regarding WPS & PQR
GTAW + SMAW for P. NO-91 Material.
8. Site transmittal No. CONS-PLN-LT-880 Ref Dated 17 th July 2020 Regarding P91 Piping
Repair and Schedule.
9. Consortium Letter No. L-SC-BV-SSP-PLN-30322 September 11 th 2020. “Re: P91 Piping
Repair Plan and Scheduled (Crack Type IV)
10. Consortium Letter No. L-SC-BV-SSP-PLN-30329 September 25 th 2020. “Re: P91 Piping
Repair Plan

Due to PLN borescope observation for Lead Pipe joint no FW-05 and FW-01 and OLV pipe
Joint no FW-01 and FW-02, we also found some excessive welding penetration same as
another joints.
1. Current condition at site, from lead pipe and OLV pipe to the turbine casing connection
not yet cut. The Manufacture detail recommendation for maintaining the casing and
valve material properties must be followed.

Picture 1. Lead Pipe & OLV Pipe - Turbine

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Picture 2. Borescope for Lead Pipe & OLV Pipe - Turbine

2. As we know, the limitation number of annealing cycle from Manufacturer on casing valve
and piping are three times. These equipment have been already annealed one(1) time at
OEM shop, then shipped to site. Also Manufacture considered that these equipment
have been already annealed one(1) time during original construction stage. With those
conditions, only remains once times annealing process. It is very clear that the
manufacturer recommendations for technical justification of lead pipe and OLV welding
problem resolve were very critical in order to maintain the whole system safety and life
performance for 30 years operation.
3. The excessive welding can create huge damage to turbine rotor during operation.
Adherent deposits form in the steam passage, distorting the original shape of turbine
nozzles and blades. These deposits, often rough or uneven at the surface, increase
resistance to the flow of steam. Distortion of steam passages alters steam velocities and
pressure drops, reducing the capacity and efficiency of the turbine. Where conditions are
severe, deposits can cause excessive rotor thrust. Uneven deposition can unbalance the
turbine rotor, causing vibration problems. Also the common problem of turbine path are
Erosion. Erosion of turbine blades results in rough, uneven surfaces that alter steam flow
paths. This reduces turbine efficiency and can also limit capacity. Erosion at the high-
pressure end of a turbine is usually caused by solid particles (usually iron oxide) present
in the steam. From that points of view, it is clear that the Lead Pipe joint no FW-05 and
FW-01 and OLV pipe Joint no FW-01 and FW-02 also need to cut to avoid the negative
risk on turbine systems.
4. The cutting of the Lead Pipe joint no FW-05 and FW-01 and OLV pipe Joint no FW-01
and FW-02 will affected the whole geometry (fit-up). Up to now, the consortium of SC-
BV-SSP were not performed the mock up test in order to gathered technical data for
analysis purpose. From the mock – up test we can gather specimen for:
 Mechanical test
 SEM
 Stress analysis input data
 Cross weld creep resistant test.

Based on the latest cutting data, the Consortium tried to proposed buttering/weld build
almost 18mm without PWHT, and it is did not confirmed by the latest PQR. Since the
latest PQR did not represent the actual condition and whole thermal cycle applied
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(welding by original WPS – cut – build up – reweld by new WPS) proposed by
consortium of SC-BV-SSP. Without a scientific test, the repaired process proposed by
Consortium of SC-BV-SSP were not scientifically proven to be safely operate and did not
give negative impact on life performance degradation.

Based on the technical consideration mentioned above, PLN request Consortium of SC-BV-
SSP to made a coordination with TOSHIBA for the problem resolve on Lead pipe and OLV
pipe to ensure the safety operation and without life performance degradation for 30 years
operations.

Under no circumstances do any of the statement made in this document waive the
contractor’s contractual obligation to provide all services material/equipment’s necessary for
functional, efficient and safe plant as specified in the contract.

Thank you very much for your kind attention and cooperation.

MANAGER

CC : PUPUNG ADIWIBOWO
1. KTSK Pusmanpro Lontar Ext
2. KATIM Pusertif Lontar Ext
3. PTL PLN E

Jl Raya Mauk Ds. Lontar Kec. Kemiri Kab. Tangerang Prop. Banten
T (021) 59341425 F (021) 59341425 W www.pln.co.id Paraf ________________