Work Instruction 1 (11)

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Checked and verified by Maintenance Manager, Approved by Station Manager, Date

Date

Jan Woch _____ / _____ Sauli Lehtinen _____ /

/ 2015 _____ / 2015
Effective date Distribution
9 June 2015 HC: Respective Managers, Respective Area
SC : Docushare
Keywords Replaces
BMS, (please fulfilled)
XXXX-YY-WIxx ABSORBER SYSTEM INSPECTION

1 PURPOSED
This Work Instruction will be as the guideline for Maintenance personnel to perform
Absorber System Inspection.

2 SCOPE
This Work Instruction will be applied for Absorber System Inspection at Tanjung Jati
B Power Plant. The works not mentioned in this instruction will be performed in
accordance with drawings and appropriate specifications then will be considered to be
added in this Work Instrcution later. This Work Instruction is refer to O&M manual from
OEM.

3 RESPONSIBILITY
 The Maintenance Manager has responsibility for updating this instruction.
 The Maintenance Engineer has responsibility to control maintenance works made
according to the instruction and co-ordinate with other teams during planning and
report activities to the Maintenance Manager.
 The Maintenance Engineer and Supervisor have responsibility to plan, supervise and
report of maintenance works which are undertaken in accordance with this procedure.
 The Maintenance Technician has responsibility to implement the Works Instruction in
safe manner.
 Work Instruction 2 (11)
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4 DETAIL OF WORKS
4.1 Preparation
1. Work will carried out during Outage.
2. Work should be carried out by 15 peoples and distribute in several area in group.
3. Prepare all necessary documents (Easy Laser D279 Instructions Manual Doc. No. 05-
0100 REV 7 - EASY LASER D279 and inspection report form prior to start of work).
4. Prepare the necessary parts, tools and equipment before commencing actual work.
5. Confirm that the equipment is isolated and a permit to work is available before
commencing work.
6. Prepare a suitable lay-down area.

4.2 Tools and Others

4.2.1 Personal Protective Equipment
1. Hand Gloves
2. Safety Glasses
3. Ear Plug or Ear Muff
4. Full Body Hardness

4.2.2 Consumable Material

1. Silicon Oil
2. WD 40
3. Cotton Rag
4. Molykote
5. Dow Corning 111
6. Abrasives Paper
7. Plastic Blanket

4.2.3 Spare Part

Detail List of spare parts use for Absorber System Inspection available on attachment 1.

4.2.4 Tools and Special Tools

1. Socket set: 10 mm, 11 mm, 12 mm, 14 mm, 19 mm, 29 mm, 30 mm, 34 mm.
 Work Instruction 3 (11)
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2. Spanner set: 10 mm, 11 mm, 12 mm, 14 mm, 19 mm, 29 mm, 30 mm, 34 mm.
3. Hammer, punch, screw driver set, measuring tape.
4. Fire hose and nozzle 2 ½ Inch.
5. DC Lamp set.
6. Cable roll.
 Work Instruction 4 (11)
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4.3 Opening top manhole

1. After 12 Hours Boiler Force Cooling, the fan system will be shut down.
2. Please open outlet duct manhole (2 manholes), bypass duct manhole, cone absorber
manhole, intermediate manhole, absorber distribution pipe manhole (the location in
north side) and inlet duct manhole.
3. Please contact safety man to do gas test (already requested by PTW Officer).
4. After clearance and stated the gas and temperature is safe for entrance, please start
to do the works.
5. First time after gas test, please do rough inspection with taking picture by camera to
record major defects before cleaning work (especially about plugging on the mist
eliminator trays and defect on the mist eliminator spray pipes).

4.4 General Cleaning by Fire Hydrant

1. By arrangement fire hose connect to fire hydrant please start to do general cleaning
from outlet duct, absorber cone, mist eliminator tray & pipe (both primary &
secondary tray), Absorber Distribution Pipe, perforated tray and inlet duct.
2. The cleaning purposes are only to clean generally the remaining deposit and
accumulation gypsum (mainly on the mist eliminator trays).
3. During this cleaning, please do flushing also for condensate drain of every
expansion joint to ensure the drain line is clear and no plugging by sedimentation.
4. During this cleaning, please evacuate others group under the cleaning elevation .

Casing of coupling Blower-GB Casing of coupling GB-Motor

 Work Instruction 5 (11)
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4.5 Outlet Duct Inspection

1. After cleaning and drying the outlet duct, together with Polyline please do flake
glass lining inspection and mark defected lining for repair (don’t forget to take
picture as documentation).
2. For next, Polyline personnel will do flake glass lining repair.
3. Coordinate with scaffolding personnel if Polyline need access for repairing on the
high elevation for roof and wall.
4. Please inspect and record (by take picture) defect on the Outlet Duct Expansion
Joint for both GG-X509 and GG-X510. Inspect also the flake glass lining on the
channel expansion joint which many time defected and causing leakage during
normal operation.
5. Please inspect also the hastalloy lining of slope stack on the joint lining welding
(especially on the corner) put marking for repair next day. Leakage indication is
surrounding the leakage point the hastelloy lining plate look like wet by
condensation under the lining.
6. Please repair the leakage hastelloy lining by welding use hastelloy electrode.

4.6 Bypass Duct Inspection

1. After drying please inspect the bypass duct plate (especially on the floor), whether
any defect or not (don’t forget to take picture as documentation). Bypass duct is no
flake glass lining.
2. Please repair defected plate by additional plate and welding.
3. Coordinate with scaffolding personnel if need access for repairing on the high
elevation for roof and wall.
4. Please inspect and record (by take picture) defect on the bypass duct expansion joint
GG-X507 and GG-X508.
 Work Instruction 6 (11)
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Coupling spacer Blower to Gear Box

4.7 Mist Eliminator Pipe, Nozzle & Tray Inspection

1. Please do inspection, recording and maping secondary tray base on the inspection
report form secondary tray (please find the attachment).
2. Please do inspection, recording and maping primary tray base on the inspection report
form primary tray (please find the attachment).
3. Please do inspection, recording and maping primary tray under spray pipe and nozzle
base on the inspection report form primary tray under spray pipe and nozzle (please
find the attachment).
4. Please do inspection, recording and maping secondary tray upper spray pipe and
nozzle base on the inspection report form secondary tray upper spray pipe and nozzle
(please find the attachment).
5. Please do inspection, recording and maping secondary tray under spray pipe and
nozzle base on the inspection report form secondary tray under spray pipe and nozzle
(please find the attachment).
6. Put the mark on the defected or and pluggerd nozzle by red baricade for next cleaning,
unplugging or repair.
7. Don’t forget to take picture as documentation.
8. Please do mechanical cleaning by round bar for the hard plugged mist eliminator trays
by stalactite built up for both of primary and secondary tray.
9. Please remove all spray nozzles and keep on the proper bin for inspection and manual
cleaning inside the nozzle.
10. Please repair defected pipes by special vynil ester resin.
11. After repair pipes please do flushing, inspection and unplugging the pipes from mud
 Work Instruction 7 (11)
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and some pieces shell one by one header (totally 15 header). Please coordinate with
operator for manufer the valves and for not interfere the second unit FGD absorber
operations.
12. After pipe is clear for pluuged material and the nozzle also clean, please reinstall all
nozzle to the lateral pipes. Please replace some defected nozzles.

Arangement Installation Easy Laser Alignment

4.8 Absorber Recirculation Nozzle & Pipe Inspection

1. Please do inspection, recording and maping absorber recirculation nozzle and pipe
based on inspection report form absorber recirculation nozzle and pipe (please find
the attachment).
2. Put the mark on the defected or and pluggerd nozzle by red baricade for next cleaning,
unplugging or repair.
3.
4.
5.
6.
7. .
1. Please loosen and remove hub coupling spacer bolts by spanner 11 mm.
2. Then continue with removal the hub coupling spacer and put on the suitable laydown
area.
3. By outside micrometer, please measure the disctance of the coupling spacer (design
reference by Hibon is 177.65 mm). If necesarry press and pull repeatly (flexible) the
coupling spacer to reach design reference value
4. By inside micrometer, please measure the distance between blower coupling hub and
 Work Instruction 8 (11)
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gearbox high speed hub (design reference by Hibon is 177.85 mm). If necesarry move
the motor away from the gear box to reach design reference value.

4.9 Perforated Tray Inspection

4.10 Inlet Duct Inspection
4.11 Stalactite Cleaning
4.12 Oxidation Air Distribution Pipe Inspection
4.13 Absorber Agitator Inspection
4.14 Absorber Recirculation Suction Valve Inspection
1. After both of reading value for hub to hub distance and spacer lentgh are close to the
design value, please re-install the spacer and tightening all the coupling spacer bolts
by spanner 11 mm for alignment.
2. Mount/place the easy laser alignment bracket with suitable fixtures on both of gear
box low speed shaft and motor.
3. For next steps 3 to step 30 is similar with alignment Blower to Gear Box step 3 to step
30.
Result of reading Gear Box to Motor Easy Laser Alignment

Required values for gear box to motor as per manufacturer design.

Description Required Values
Coupling Spacer Length 177.65 mm
Hub to Hub Gap 177.85 mm
 Work Instruction 9 (11)
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Vertical Offset -0.09 mm +/-0.02 mm gear box low

Horizontal Offset +0.0 mm +/-0.02 mm
Coupling Hub Face Vertical Angular 0 ~ 0.02 mm
Coupling Hub Face Horizontal Angular 0 ~ 0.02 mm

4.15 Testing and Recording Completion of Work

1. After inform, get permition (from PTW officer) and coordinate with operator, please
do running test, record bearing vibration parameter and temperature, record discharge
pressure, inlet valve opening, setting ampere and flow through absorber.
2. While in progress running test, please do nice housekeeping to clean our work place
from exused spare parts, remaining consumable, cotton rag and other rubbish. Also
please check and clean our tools (keep our personal tools is complete) to do next other
works.
3. After blower performance is acceptable, please do not forget to closed the PTW and
handed over the blower to operator to operate and monitor the operational parameter
to follow normal operation.
4. All data should be recorded in the inspection report form (replacement parts record
and vibration data record).
5. Supervisor will keep those inspection reports and upload to Work Order attachment in
Maximo during finishing (including fulfilling actual date started & finished,
Competence Person and engineering comment).

5 REFERENCE
1. Easy Laser D279 Instructions Manual Doc. No. 05-0100 REV 7 - EASY LASER
D279.

6 ATTACHEMENT
1. List of spare parts use for Absorber System Inspection.
2. Easy Laser D279 Instructions Manual Doc. No. 05-0100 REV 7 - EASY LASER
D279.
 Work Instruction 10 (11)
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3. Inspection report form.

4. Alignment data record new oxidation air blower C.
5. Vibration data record.
6. Print out result of easy laser alignment D279.
 Work Instruction 11 (11)
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1. List of spare parts use for Absorber System Inspection

No Description
. Item Quantity
SHIM. - SHEET. ROLL. LENGTH: 1200 MM. WIDTH: 150 MM.
1 58-16-15-189 THICK: 0.4 MM. MATL: SS304 1 ROLL

SHIM. - SHEET. ROLL. LENGTH: 1200 MM. WIDTH: 150 MM.

2 58-16-15-191 THICK: 1 MM. MATL: SS304 1 ROLL

SHIM. - SHEET. ROLL. LENGTH: 1200 MM. WIDTH: 150 MM.

3 58-16-15-186 THICK: 0.07 MM. MATL: SS304 1 ROLL

SHIM. - SHEET. ROLL. LENGTH: 1200 MM. WIDTH: 150 MM.

4 58-16-15-187 THICK: 0.01 MM. MATL: SS304 1 ROLL

SHIM. - SHEET. ROLL. LENGTH: 1200 MM. WIDTH: 150 MM.

5 58-16-15-188 THICK: 0.03 MM. MATL: SS304 1 ROLL

SHIM. - SHEET. ROLL. LENGTH: 1200 MM. WIDTH: 150 MM.

6 58-16-15-190 THICK: 0.5 MM. MATL: SS304 1 ROLL

SHIM. - SHEET. ROLL. LENGTH: 1200 MM. WIDTH: 150 MM.

7 58-16-15-185 THICK: 0.05 MM. MATL: SS304 1 ROLL

SHIM. - SHEET. ROLL. LENGTH: 1200 MM. WIDTH: 150 MM.

8 58-16-15-192 THICK: 2 MM. MATL: SS304 1 ROLL

SHIM. - SHEET. ROLL. LENGTH: 1200 MM. WIDTH: 150 MM.

9 58-16-15-193 THICK: 3 MM. MATL: SS304 1 ROLL