FR-0120 INSPECTION FINDINGS

Sl. No. FINDINGS RECOMMENDATIONS STATUS ACCEPTED

1. Visual inspection from radiant floor was done and found bowing of all
Leg# 4,5&6 has been reported during normal operation.
1
2. Tube# 103 of Coil# T found with longitudinal crack.
3. Overlapping of tubes# 59-60 with 61-62 &

2 Hammer test was done for all tubes and any sign of coke was not found.

Minor bulging on Leg# 5&6 for all coils noted. Severe bulging on these
3
Leg#3 tubes # 10,15,22,27,39,51,58&87 noted.
1. Some of the burners found plugged with black coke materials.
2. Fuel Gas Tubing connectors found with signs of leak and corrosion.
4 3. Few burner tips found not align with burner tiles.
4. Burners# 1 & 23, type S3 tips were found damaged due to oxidation.
1. Remove and clean all burner tips and Fuel Gas Tubing
connectors by air/steam.
2. Carry out painting for connectors as per APCS-2A coating
system.
3. Create a groove in the burner tile to allow normal firing. ONGOING
4. Replace corroded connectors with in-kind material.
5. Burners# 1 & 23, type S3 tips replace with in-kind
materrial.

Due to movement of the radiant tubes, bricks were found fallen in the
Remove all radint floor bricks, clean and rearrange as per
5 trough near Tube# 6-12, 17-18, 19-27, 31-42, 43-52, 65-66, 67-76, 81-90,
engineering drawing.
91-102
1. Castable refactory in the trough found damaged due to touching of
bottom guide pins.
2. Castable refractory on the west side in between burners 17-18 was
6 Repair the damaged castable with Golite 125
found sucked in and is suspected to have severe damages. After removing
the bricks it was found the castable refractory is damaged with wide deep
cracks.

7 Both side Shielding wall bricks found inplace. For information.

1. Radiant brick wall at peep window# W12/13/14/15, N11/12, E4/5 was

8 found popped out to approxiamtely 15.0mm. Repair the bricks with high temperature mortar.

Decoke Nozzles Pipes:

9 1. All 8 decoke nozzle pipes in good condition without any erosion For information.

Decoke Tiles:
10 Decoke nozzle# W2/4 Tiles castable blocks found with through cracks. Replace with in-kind material tiles.

Ceramic fiber insulation between decoke pipe and sleeve found

11 Repalce with new blankets.
shrink/damaged for all nozzles.

12 All decoke nozzle found with loose coke material Clean all nozzles.

1. Loose coke material found on radiant floor bricks.
13
2. Big gap in floor bricks around decoke nozzles was observed.
Ceramic fiber from the radiant wall brick lining found shrink/missing from
14
the expansion joints.
1. Minor cracks on all burner tiles recfractory is found.
15 2. Burners# 5/11/14/18 tiles were found with through cracks and damaged.
1. Pilot burners are found partially plugged with loose coke material.
16
Remove all radint floor bricks, clean and rearrange as per
engineering drawing.
Repalce with new blankets.
1. Repair the cracks with high temperature mortar.
2. Burners# 5/11/14/18 tiles replace with in-kind tiles.
1. Clean all burners, based on the findings furhter
recommendations will be issued for replacement.
2. Carry out painting as per APCS-2A. ONGOING

Peep windows# W11/12/14/15, E11/E14/E15/S12 were found with severe

17 Replace all damaged windows with in-kind material.
damages

18 North side panel above manway, brciks found with minor damages. Repair the bricks with high temperature mortar.

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 1. Ceramic fiber insulation modules for the radiant wall found with gaps of
1. Repalce with new blankets.
approximately 20 to 50 mm wide. The location is at both sides in between
2. Repair with high tempearture insulation blankets and
brick wall and second floor peep windows.
KHR45A welding rod as pins as per approved method of
2. Ceramic modules for almost all windows at second level found loose.
statement.
3. Erosion of ceamic modules above all 8 decoke nozzles approximately 50-
19 3. For informaton.
70.0mm deep and 3X3 meters area has been reported.
4. Repair with high tempearture insulation blankets and
4. Ceramic modules on ceiling near Tube# 31 found damaged.
KHR45A welding rod as pins as per approved method of
statement.

1. Front panel above the north manway was found half of the portion
20 1. Repair the panel with ceramic insulation blankets.
repaired with bricks and are found disloacted and damaged.

Leg # 1 tubes existing weld joints: 1. Clean all weld joint by power brush to carry out NDT.
Based on the findings furhter recommendations may be
issued.
21 2. Carry out touch up painting as per APCS-11C coating ONGOING
system.

Leg # 6 tubes existing weld joints:

1. Clean all weld joint by power brush to carry out NDT.

22 Based on the findings furhter recommendations may be ONGOING
issued.

COT Thermocouples existing weld joints:

1. Clean all weld joint by power brush to carry out NDT.

23 Based on the findings furhter recommendations may be ONGOING
issued.

1. Clean all weld joint by power brush to carry out NDT.

Based on the findings furhter recommendations may be
Decoke Nozzles to bottom plate existing weld joints:
issued.
24
2. Carry out touch up painting as per APCS-11C coating
system.

Decoke Nozzle Inlet Pipes to be confirmed for CUI:

25 Remove insulation to carry out visual inspection.

Four (4) Thermowells at transition section:

1. Remove all thermowells for visual and DPT.

26

Crossover PT/PG Connection: 1. Provide scaffols and Clean all weld joint by power brush
to carry out NDT. Based on the findings furhter
recommendations may be issued.
27 ONGOING
2. Carry out painting as per APCS-11C coating system.

Radiant Section top Ceiling:

1. Remove all gratings and clean the floor and call for
28
insepction to confirm top plate painting condition.

1. Coils Spring Hanger:

1. Coils Spring Hanger: Adjust Spring rods in centre of the turnbuckle to cold set at
29 8°.
2. Carry out painting as per APCS-2A coating system.

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 Transition Section:
Initial Visual inspection after opening manway was done and below are the
findings:
1. Loose coke and a bulk of castable refractory found on the floor bricks.
2. Castable refractory on the east side wall was found damaged and fallen
on the floor approximately 1.0 square meter. It is suspected that the
damaged happened during furnace cool down since damaged portion
appeared to be fresh without any scaling of coke material.
3. Few locations castable refractory found popped out and loose. Many 1. Provide scaffold to access the castable refractory to carry
small to large cracks also observed. out hammer test and assessment of pipe support.
4. ceramic fiber modules found in good condition without any noticeable 2 Intermittent baffle support cracks shared with TSD
damages. engineer for evaluation.
30 ONGOING
5. Two intermittent baffle support for convection coils found with through 3. After removing the damaged refractory call for inspection
cracks. The location of the supports is 2nd and 3rd from north manway. to carry assess the anchor integrity.
6. Hammer test was done and locations marked to remove the 4. Replace the damaged/deformed manway support plates
loose/poppedup refractory. with SS310 in-kind material.
6. Both side manway supports plates found damaged/deformed due to
oxidation.

Convection Section:
7th Leval Manway: Moderate amount of fouling observed on the finned
31 pipes. Castable refractory found in good condition with minor cracks and
few chips. Accessible Support found in good condition without any
mechanical damages/deformation.
1.Remove TE-1291 (10th floor), TE-1292/99 (6th floor) &
TE-1293/94/95 (5th floor) to carry out DPT examination.
2. Remove front panels to perform UT for bends. ONGOING
3. Carry out cleaning at 7th level as per OPS/PED procedure.

Stack
1. Clean the piping spool and paint with APCS-26 coating
1. Piping spool connected to PG-1296 was found with paint damage and
system.
32 minor corrosion on the valve bode and flange connection including
2. Repalce nut/bolts of the flange connection with in-kind
nots/bolts.
material.
3. Provide scaffold for internal inspection.

B-0150 Expansion Bellows:

33

1. Open manway of the blower and provide permit for

inernal insepction.
Damper Plate:
34

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