RAS TANURA REFINERY RESD/INSPECTION UNIT Box 7790, Tel: 673-5207, Fax: 673-2812 May 25, 2002 INSPECTION POST T& REPORT FOR LER i 3 RESD/RUI-124/02 SUPERINTENDENT Refinery Plant Utilities Division Box 7030 Ras Tanura Attached please find the RESD/Inspection Post-T& report for High Pressure Boiler #9. The subject boiler was shutdown on February 9" 2002 on an emergency basis due to the concurrent of 7 screen tubes and rear wall tubes that had failed while the boiler was in service. The EIS ‘T&d originally scheduled for May 2002 was brought forward to be carried out in conjunction with the emergency shutdown. The emergency shutdown was completed on March 19” 2002. This report includes the Inspection field findings and completed repairs along with the Post T8d recommendations. The internal inspection revealed that the steam drum, mud drum and headers were found in good condition, The boiler tubes were in poor condition and required replacement as soon as Possible. The corrosion rate as evaluated on the basis of the corrosion coupons was determined to be negligible, Based on the current Boiler Condition Assessment (BCA), Previous Remaining Life Assessment survey and the fact that the Inspection Pre-T&I recommendations for retubing were not carried out due to material unavailability, the boiler is considered unreliable for continued service per its current 24 month EIS operation interval ‘The major work items accomplished during this shutdown were as follows: 1. During this shutdown, the second Boiler Condition Assessment (BCA) was completed ‘on the main bank tubes by Dhahran Inspection Personnel using MFL and submerged UT testing equipment and the result was found similar to the RESD/Inspection initial Remaining Life Assessment results. A total of 160 main bank tubes were found below TM. For more details please, refer to the ID/OLD/ITU/L-52/2002 and ROED letter #ROED-5081/2002 2, Replacement of twenty (20) tube sections from the lower screen tubes and rear tubes. due to severe bulges and leaking. 3. Minor refractory repairs were completed along the knuckle area, around the burners and at superheater areas. 4. Hydrojeted clean the boiler main bank tubes including the main fuel gas header and associated piping. If additional information is required, please call Mohammed.H Quraish on 673-1930, or Ahmed A Ghashi on 673-7617.RESD/RUI-124/02 A. A Ghashi, field Supervisor RESD/Inspection Unit ae Piibbosh. sfasfrr esas cc Gen. Supyr. RESD W-2600, RT ‘Supt., RMUD, B-7230, RT Supt., RMSD, B-7360, RT Supvr., ROED/Utlities Unit, B-7500, RT Supvr., RMTSD/ TE Unit, B-7150, RT Supvr., Inspection Unit. Foreman, ROD/Plant 30-1, B-7270, RT Letterbook/FileINSPECTION POST T&I REPORT FOR H. P. BOILER #: iT 30-1 IMMARY OF THE INSPECTION ATI FIREBOX: The firebox manways were opened for inspection. The initial leak hydrotest at 750 psig was successfully performed on the boiler tubes after patch weld the leaking tubes in the screen and rear tubes with no additional tube or roll leaks observed. The internal inspection was conducted in the firebox and found in good condition with the exception of a total of 17 severe bulges on the lower screen tubes. The bulged tube sections were replaced in-kind. The external surfaces of the screen tubes and water wall tubes were found covered with a soft layer of combustion products and a thin layer of scale which was removed by hand tool cleaning. Three (3) sample tube sections were cut-out from the screen tubes for scale density analysis and corrosion evaluation. Visual inspection after removing sample tubes revealed heavy to moderate scattered internal scale deposits. ‘The tube section was sent to the RT Machines Shop for specimen preparation and then to the RT Lab for scale density analysis. The highest scale density result was 1326 g/m? , which is well above the mandatory chemical cleaning level of 1000 g/m? as per SAEP-1025. However, the chemical cleaning was not recommended due to very poor boiler tube condition. All the removed tube sections were replaced with new tube sections and all the field welds were radiographed with acceptable results. Minor refractory repairs were made around the knuckle area and on the main bank areas using AP Cast 94 refractory material. The floor tiles from three (3) locations of the firebox were removed to allow inspection of the floor tubes. The floor tubes were visually inspected after cleaning and found in satisfactory condition. UT gauging of the floor tubes at the cleaned areas showed no metal loss. UT gauging of the water wall, roof, screen and main bank tubes at the data points revealed no significant metal loss. All results were recorded in the equipment file. The burners and the main fuel gas burner tips were visually inspected after sandblasting and found in good condition, AIR DUCT AND STACK: The intake ducting, exhaust ducting and the stack were opened cleaned inspected and found in good conditionINSPECTION POST T&I REPORT FOR H. P. BOILER #9, PLANT 30-1 STEAM DRUM; The steam drum was opened and the visual internal inspection revealed no sign of oil or scale deposits. All the internals were removed and the internal surfaces of the vessel as well as the tube ends were inspected and found in good condition. UT gauging of the shell and heads revealed no metal loss. The tube ends and ID's were visually inspected and found to be in acceptable condition with general pitting corrosion attack at the rolling area of the main bank tubes. The previously reported grooving and the linear pitting corrosion attack on the tube ends of the main bank area were found in the same condition as observed during the last T&I. The corrosion coupon was removed, cleaned and evaluated for metal loss. The corrosion rate was determined to be 0.59 mils per year, which is considered negligible. ‘The same corrosion coupon was reinstalled for another 2-year service run. The steam drum internals were visually inspected after condensate wash cleaning and found in good condition. The internal components were installed and inspected for tightness and all were found secure and in position. MUD DRUM: The mud drum was opened and visually inspected before cleaning and revealed no sign of oil or scale deposits. The bottom angle plate was removed for inspection and the internal surfaces of the vessel including the tube ends were visually inspected and found in good condition. UT gauging of the shell and heads showed no metal loss. The tube ends and ID’s were visually inspected and found to be in acceptable condition with general pitting corrosion attack at the rolling area of the main bank tubes. The previously reported grooving and the linear pitting corrosion attack on the tube ends were found in the same condition as observed during the last TU. The corrosion coupon was removed, cleaned and evaluated for metal loss. The corrosion rate was determined to be 0.57 mils per year, which is considered negligible. The same corrosion coupon was reinstalled for another 2-year service run. The internal bottom plate was visually inspected after condensate wash cleaning and found in good condition. It was installed in place, inspected for tightness and found secure.INSPECTION POST T&I REPORT FOR BOILER #9, PLANT 3 SUPERHEATER TUBES AND HEADERS: The superheater tubes as well as the inlet and outlet headers were externally inspected and were found in good condition. U/T gauging of the headers revealed negligible metal loss. The main bank and rear wall tube area bottom skin cover plate was removed completely to repair the two leaking tube sections at the mud drum. The embedded elbows were exposed for inspection evaluation and found severe external corrosion attack take place on the elbows due to the entrapped sulfur. The sulfur combining with high humidity forms sulphuric acid during shutdowns. The corroded elbows were replaced in-kind. New ¥%” thick carbon steel plate was fabricated, installed and seal welded on the bottom area of the main bank tubes. UPPER AND LOWER WATER WALL HEADERS: All the hand hole plugs of the upper and lower headers were removed for inspection. The headers were visually inspected and found to be in good condition. All the hand hole plugs were visually inspected after cleaning and found a total of 12 plugs in very bad condition due to severe external corrosion on the gasket surfaces. The corroded plugs were replaced in-kind and the remaining plugs were reinstalled with new gaskets. U/T gauging of the headers found no significant metal loss. MISCELLANEOUS: . During this shutdown, the second Boiler Condition Assessment (BCA) was completed on the main bank tubes by Dhahran Inspection Personnel using MFL and submerged UT testing equipment and the result was found similar to the RESD/Inspection initial Remaining Life Assessment results. A total of 160 main bank tubes were found below TM. For more details please, refer to the ID/OLD/ITU/L-52/2002 and ROED letter #ROED-5081/2002 Vv .. The boiler was successfully hydrotested at 1125 psig after the completion of all scope of work items. w . The safety valves were removed to the Relief Valve Shop for servicing and testing. The valves were satisfactorily “hot pop” tested in place after the boiler start-up. 4. The two (2) 12" feed water inlet check valves were opened for inspection. The valve bodies and their flappers were inspected and found in very good condition. 5. The instrument air surge drum hand hole cover was removed and the internal surface of the drum was found cleaned and in good condition. 5INSPECTION POST T&I REPORT FOR H. P. BOILER #9, PLANT 31 MISCELLANEOUS CONT. 6. The main fuel gas header and associated piping were visually inspected after hydrojetting and found in good condition. 7. All the existing flexible hoses to the main fuel gas burners were successfully hydro tested at 18 psig. 8. The F. D. Fan Turbine coolers were opened for cleaning and inspection. The shell and internal parts were visually inspected after cleaning and all were found in good condition. POST T&I RECOMMENDATIONS: 1. Replace/retube the entire boiler tubes as per CSD and Inspection recommendations. For more details please, refer to the CSD recommendations in the letter CSD-L-801/2000, Inspection Operation Department letter ID/OID/ITU/L-52/2002 and Inspection recommendations in the letter RESD-I- 30-1-9-076/97. 2. Remove the safety valves to the Relief Valve Shop for servicing and testing and perform a hot pop test after start-up. 3. Remove all internals of the steam and mud drums for cleaning and inspection.