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FINAL REFRACTORY Unit-1 erection year: 2016

INSPECTION REPORT
Refractory dry-out: Aug 2017

Number of shutdowns/start-ups
Client: PT Cikarang Listrindo between outages 2018-2019: NA
Energy

Scope: Refractory inspection of

Broeye Finland Ky project VALMET CYMIC- Unit 1 Main Fuel:
number:19010-2019 (135MWe). - Coal app. 90%
- Biomass(PKS) app. 10%*
Client PO: 19/00962-NJ - Other 0%
*1 month biomass test only

Author: Pasi Viemerö Contact: pasi.viemero@broeye.com

+358400297094

Unit-1 inspection dates: 31.08. – 01.09.2019 Site location: Cikarang-Bekasi, Indonesia

Cikarang Listrindo distribution: Lining Tec Oy distribution:

Mr. Duriman Efendi (duriman.efendi@listrindo.com) Mr. Jorma Pitkänen (jorma.pitkanen@liningtec.fi)
Mr. Sami Sivola ( sami.sivola@listrindo.com )

REFRACTORY INSPECTOR WORK TIME: LOCAL REFRACTORY COMPANY: SITE TEMPERATURE:

∙‫ ٭‬08.00 – 17.00 ‫ ٭‬Dipta Prima (Leader Mr. Sugino) ‫ ٭‬+26-34°C

REFRACTORY INSPECTION REPORT, WEEK 35 / 2019

- Refractory lining inspection starts immediately, inspection reveals condition of existing

refractory lining in lower furnace as follows:

Area Condition

Furnace, lower part:

- Grid Only partial areas covered by refractory, mainly in good condition.

- Grid-step Mainly in good condition, only minor area broken on rear-wall

central section.

- Front-wall Plain walls are mainly in good condition. Some cracking appears
thru-out refractory linings, as result of thermal movements. Cracking
may lead to minor surface spalling over time, some signs of surface
spalling verify.
Front-wall present minor surface deposit.

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Few secondary air opening lower parts present signs of erosion.

Kick-out refractory lining present erosion signs on central section.

- Fuel feeding All internal refractory cylinders are mainly in good condition.
openings All outlets and lower parts are mainly in good condition.
All upper parts present abnormal cracking and partial spalling. It
seems, that upper parts could be exposed to some temperature
variations, caused by combustion and secondary air flow.

- Rear-wall Plain walls are mainly in good condition. Some cracking appears
thru-out refractory linings, as result of thermal movements. Cracking
may lead to minor surface spalling over time, some signs of surface
spalling verify.
Few secondary air opening lower parts present signs of erosion.
Kick-out refractory lining is mainly in good condition.

- Return duct Left side return duct opening present broken vertical outlet corner
openings lower part (left side).
Left side return duct opening present heavy cracking on vertical
outlet corner lower part (right side).
Right side return duct opening present heavy cracking on vertical
outlet corner lower part (both sides).

- Left sidewall Plain walls are mainly in good condition. Some cracking appears
thru-out refractory linings, as result of thermal movements.
Bottom ash cooler inlet opening is mainly in good condition.
Ash cooler air separator openings are mainly in good condition.
Kick-out refractory lining is mainly in good condition.

- Start-Up Burner 1 Internal cylinder mainly in good condition.

(front-wall side) Upper part mainly in good condition.
Lower part present partial minor surface spalling.
Lower part present some slag deposit.

- Start-Up Burner 2 Internal cylinder mainly in good condition.

(rear-wall side) Upper part mainly in good condition.
Lower part mainly in good condition.

- Right sidewall Plain walls are mainly in good condition. Some cracking appears
thru-out refractory linings, as result of thermal movements.
Bottom ash cooler inlet opening is mainly in good condition.
Ash cooler air separator openings are mainly in good condition.
Kick-out refractory lining is mainly in good condition.

- Start-Up Burner 3 Internal cylinder present lower area erosion.

(rear-wall side) Upper part mainly in good condition.
Lower part present partial heavy surface spalling.

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- Start-Up Burner 4 Internal cylinder mainly in good condition.

(front-wall side) Upper part mainly in good condition.
Lower part mainly in good condition.

- Division Wall Plain walls are mainly in good condition. Some cracking appears
thru-out refractory linings, as result of thermal movements.
Approximately 1800mm of front-wall side corner (from grid curb
upwards) has been repaired already during past outages and now
1800mm-3000mm present heavy cracking and reparation required.
Approximately 3000mm of rear-wall side corner (from grid curb
upwards) present broken refractory lining with heavy cracking and
reparation required.

Set of pictures with comments, to partly clarify status of present refractory lining in lower
furnace:

Refractory Grid-step is mainly in good condition, only small area is broken on rear-wall central
section. Since 50% of the horizontal step remain, failure is mainly cosmetic problem and no
reparation recommended. Reparation required, in case heavy erosion appears on surrounding
mechanical grid nozzles during upcoming outages.

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Front-wall refractory lining is mainly in good condition, only normal cracking caused by thermal
movements and minor surface deposit.

While introducing alternative fuels for combustion, it is common for some surface deposit to start.

Some of lower furnace secondary air opening lower parts present signs of erosion. No reparations
required during this outage, however some renovations recommended during next outage, which
will be presented later in this report.

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Corners, sidewalls and rear-wall kick-out refractory linings are mainly in good condition.

Front-wall kick-out refractory lining is mainly in good condition near sidewalls.

Front-wall kick-out refractory lining central section (length app. 5000mm) present some erosion.
Since erosion appears mainly on surface, refractory thickness remains within acceptable tolerance
and no reparation required. To be monitored during upcoming outages, whether erosion rate
stabilize or accelerates.
It is expected to stabilize, however in case erosion continues, reparation requirement evaluated
during next inspection.

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Fuel feeding openings 1 and 2 present some cracking and spalling on upper part. It is recommended
to remove all loose refractory pieces, dismantle original refractory up to 70mm depth, create arch-
shape to surrounding edges and re-cast by use of plastic ramming material.

Furnace rear-wall is mainly in good condition, no any surface deposit on plain walls.

Plain wall cracking may lead to minor surface spallings over time.

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Left side corner of the return duct (left) presented broken refractory lining during inspection. It was
noted, that refractory studs have become loose and failed support refractory lining. App. 1200mm
upwards was cracked and reparation required on both sides of left return duct opening.

Right side return duct outlet corners were verify cracked and hollow by hammer test. App. 1800mm
upwards is recommend to repair.

During manual demolition of deteriorate refractory linings, was verify, that almost all refractory
studs at the area became loose only by gentle touch. Situation is highly abnormal and should be
further investigated by welding expert.
All remove studs recommended to be recovered before re-casting.

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Both plain sidewall refractory linings are mainly in good condition.

Inlet openings to ash cooler and ash cooler air separator openings are in good condition.

Start-Up Burner 1 present some slag deposit on lower slope and recommended to clean out. Area
present also some minor coating spalling, however since refractory lining remain within acceptable
tolerance, no reparation required.

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Start-Up Burners 2 (left photo) and SUB 4 (right photo) are mainly in good condition.

Start-Up Burner 3 present more coating spalling on lower part and vertical sides. Since reefractory
thickness remain within acceptable tolerance, no reparation required during this outage. It is
recommended to repair this area partly during 2020 outage by use of coating, plastic ramming
material or Low Cement castable. Reparation method to be verify later, when/if hydro demolition
equipment and stud welding equipment available. If manual demolition by use of jackhammers is
only option, some original studs may remove.

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Start-Up Burner 3 present heavy erosion on internal cylinder lower part and recommended to repair
by use of plastic ramming material.

Division Wall present lower corners partly broken, partly heavy cracking. Refractory lining has
failed because refractory studs have become loose. During manual demolition, lot of studs were
remove by gentle touch. Quality of stud welding should be further more investigated.
All remove studs recommended to be recovered before re-casting.

Inspection continues in Bottom Ash Cooler, revealing existing refractory lining as follows:

Area Condition
Ash Cooler, left side:

- Lower wall area Furnace outlet present exposed tubes and reparation recommended.

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Front side present heavy cracking and reparation recommended.

Ash Cooler, right side:

- Lower wall area Furnace outlet present exposed tubes as heritage from first erection
period. No reparation recommendation, however tube thickness
measurement required during every outage.

Front side present exposed tube and reparation recommended.

Set of pictures with comments, to partly clarify status of present refractory lining in Bottom
Ash Coolers:

Left side photo presenting bottom ash outlet from furnace in left side Bottom Ash Cooler. All loose
refractory pieces to be removed out of process, 25mm studs to be weld on tubes by use of tig-
welding machine and re-cast by use of Morflo 170D.
Right side photo present exact same location in right side Bottom Ash Cooler. Execution of
refractory lining variates from left side BAC, leaving tubes exposed since first erection time. No
refractory reparation required, however tube thickness measuremnets recommended during every
outage.

Small area cracking and spalling in both BAC. Remove loose pieces, add studs if no anchors and re-
cast by use of Morflo170.

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Inspection continues in upper furnace, revealing existing refractory lining as follows:

Area Condition
Furnace, upper part:

- SuperHeaters Plain walls are mainly in good condition. Some cracking appears
thru-out refractory linings, as result of thermal movements.
SH 4 and 5 present some patch repair on front-wall upper part.
Front-wall internal refractory lining designed to end on tube surface.

- Flue gas opening to Plain walls are mainly in good condition.

inlet duct Vertical refractory edges are located to membranes, instead of design
tube crown.

- Roof area Mainly in good condition.

Set of pictures with comments, to partly clarify status of present refractory lining in upper
furnace:

Superheater plain walls are mainly in good condition.

SH 4 and 5 present some patch repair on front-wall upper part. it is recommended to remove
additional refractory thickness, overlay-weld all tube erosion marks and re-cast according to
original design.

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Front-wall internal refractory lining designed to end on tube surface. Some cracking and spalling
verify in all SuperHeaters, however since no visible erosion marks on adjacent tubes, no reparation
recommendations.

Both flue gas openings to Inlet duct are mainly in good condition.

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Lower and upper aprts of flue gas openings mainly in good condition.

Flue gas opening vertical refractory edges are located to membranes, instead of design tube crown.

By leaving refractory to fin, erosion tend to start on adjacent tube during times. Some metal-spray
peelings already verify, most likely some erosion marks upcoming during next operational season.
It is recommended to repair target to meet design later in this report.

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Furnace roof area refractory linings mainly in good condition.

Inspection continues in Inlet ducts and Cyclones, revealing existing refractory lining as
follows:

Area Condition
Cyclone (left):

- Roof Scaffolding available for close inspection.

Mainly in good condition.

- Inlet duct Scaffolding available for close inspection.

Mainly in good condition.

- Cylinder walls, No full area scaffolding, distance view inspection.

upper part Appears to be in normal condition. Some surface erosion appears on
target zone.

- Cylinder walls, No scaffolding available, distance visual inspection.

lower part Appears to be in normal condition. Only some flow marks on
refractory segments, impossible to see if some surface deposit
creation.

- Conical part No scaffolding available, distance visual inspection.

Appears to be in normal condition. Some flow marks.

- Dipleg No scaffolding available, distance visual inspection.

Cyclone (right):

- Roof Scaffolding available for close inspection.

Mainly in good condition.

- Inlet duct Scaffolding available for close inspection.

Mainly in good condition.

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- Cylinder walls, No full area scaffolding, distance view inspection.

upper part Appears to be in normal condition. Some surface erosion appears on
target zone.

- Cylinder walls, No scaffolding available, distance visual inspection.

lower part Appears to be in normal condition. Only some flow marks on
refractory segments, impossible to see if some surface deposit
creation.

- Conical part No scaffolding available, distance visual inspection.

Appears to be in normal condition. Some flow marks.

- Dipleg No scaffolding available, distance visual inspection.

Set of pictures with comments, to partly clarify status of present refractory lining in Inlet
ducts and Cyclones:

Both Inlet duct refractory linings are mainly in good condition.

Both Cyclone roof refractory linings are mainly in good condition.

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Both Cyclone upper cylinder present some surface erosion marks on target zone.

Surface erosion appears only in millimeters, normal situation and no reparation requirements.

All off-target walls and conical walls are mainly in normal condition from disttance.

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Photo presenting Dipleg view from Loopseal floor. Refractory lining appears to be in normal
condition, no any surface deposit.

Inspection continues in Manifold ducts, revealing existing refractory lining as follows:

Area Measure
Manifold duct (left):

- Vortex cylinder Refractory lining mainly in good condition.

- Walls Partial scaffolding available.

Appears mainly in good condition.
No surface deposit, which may start to accumulate with biomass.
Some surface cracking and spalling, since first line of Sling-Coils
have been in contact with refractory lining.

- Roof Partial scaffolding available.

Appears mainly in good condition.

- Floor Mainly in good condition.

Only minor fly-ash deposit on floor.

- Expansion joints Mainly in good condition.

Roof mechanical plate present some bending downwards.

- Outlet to Back-pass Mainly in good condition.

Manifold duct (right):

- Vortex cylinder Refractory lining mainly in good condition.

- Walls Partial scaffolding available.

Appears mainly in good condition.
No surface deposit, which may start to accumulate with biomass.

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- Roof Partial scaffolding available.

Appears mainly in good condition.

- Floor Mainly in good condition.

Only minor fly-ash deposit on floor.

- Expansion joints Mainly in good condition.

Roof mechanical plate present some bending downwards.

- Outlet to Back-pass Mainly in good condition.

Set of pictures with comments, to partly clarify status of present refractory lining in Manifold
ducts:

Both Manifold duct Vortex cylinder areas are mainly in good condition. No any surface deposit or
major erosion signs verify.

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All Manifold sidewalls are mainly in good condition.

Left side Manifold duct present some surface cracking and spalling, since first line of Sling-Coils
have been in contact with refractory lining. Now Sling coils present some bending and advice to
clean all loose refractory pieces out of the process. No re-casting requirements.

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Roof expansion joint mechanical plates present some bending downwards. To be monitored during
next outages.

Inspection continues in Loopseals, revealing existing refractory lining as follows:

Area Condition
Loopseal (left):

- Floor Mainly in good condition.

- Walls Plain walls are mainly in good condition.

- Headers Mainly in good condition.

- Roof area Minor signs of erosion, mainly in good condition.

- Return duct Mainly in good condition.

Loopseal (right):

- Floor Mainly in good condition.

- Walls Plain walls are mainly in good condition.

- Headers Mainly in good condition.

- Roof area Minor signs of erosion, mainly in good condition.

- Return duct Mainly in good condition.

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Set of pictures with comments, to partly clarify status of present refractory lining in Manifold
ducts:

Both Loopseal refractory linings are mainly in good condition.

Both Loopseal and Return duct roof areas present minor erosion signs. No reparation requirement,
to be monitored during upcoming outages.

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Both Return duct refractory linings are mainly in good condition.

PROPOSED REFRACTORY LINING WORKS IN 2020 MAINTENANCE SHUT DOWN

Areas to be most likely repaired due to expected failure/damage condition and/or need for
modification:

Work Notes

Furnace Division wall corners to be checked closely

(both side 3000mm from floor upwards has
been repaired).

Return duct opening upper part corners to

be checked closely.

10 pieces of secondary opening

recommended to re-design with roof and
upgrade material to Type R.

Start-Up Burner 1 small area coating.

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Start-Up Burner 3 small area coating and

worst area re-casting.
To be offered according to Cikarang
Listrindo request.

Front-wall kick-out layer in central section

inspected closely, no reparation expectation
at this moment.

Bottom Ash Coolers No reparation expectations.

All areas to be inspected before decision of
demolition/recasting.

Superheaters Front-wall Upper edges and vertical

refractory linings inspected closely for tube
erosions. Minor reparations expected.
All areas to be inspected before decision of
demolition/recasting.

Flue gas openings to Inlet ducts
All 4 Furnace side vertical refractory edge
modification to tube crown.
For Cikarang Listrindo to consult valmet, if
it is Ok to extend refractory lining and if so,
how much?
Also Cikarang Listrindo to consult Valmet,
metal-spray required as design or not. This
information lead use of refractory studs or
Y-anchors.
Options for refractory lining modification
in priority order as follow:
- Dismantle original refractory lining
minimum 100mm, install refractory
studs and re-cast end nearest tube
crown (additional app. 35mm).
- Install refractory studs and re-cast
additional 120mm ending to second
tube crown.
- Install 2 lines of Y-anchors (1 Y-
anchor line design no good) and re-
cast additional 200mm.
In all cases, metal-sparay define
refractory lining fixing and refractory
studs are recommended as priority.

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Tube replacements for Cikarang Listrindo

to consider.

Full area scaffolding recommended.

Inlet ducts and Cyclones No reparation expectations.

Cyclones target zone erosion rate to be
inspected closely.
All areas to be inspected before decision of
demolition/recasting.
Full area scaffolding recommended.

Manifold ducts Wall area next to Sling-coils may present

deteriorate.
All areas to be inspected before decision of
demolition/recasting.

Loopseals No reparation expectations.

All areas to be inspected before decision of
demolition/recasting.

Conclusion:

- According to received information, some melted bed material (”caking”) appeared

on Furnace grid Division wall area (over the mechanical grid nozzle heads),
indicating overheat temperatures (hot spots).
→ Melted deposit has most likely disturb primary air fluidizing via grid
nozzles,causing more area overheat.
→ Overheat has most likely caused/supported Division wall lower corner refractory
lining failure.

- Refractory lining failure on Return duct opening corners appears to be caused by

weak refractory stud weldings and quality of the welding should be further more
investigated by professionals.

- There is huge amount of designed refractory lining in CFB-Unit. Refractory lining

must be maintained as well as possible. Repair methods, installation procedures
and material selections should always follow given recommendations.
It is strongly adviced not to test any refractory materials without prior process
experience.
→ There is lot of refractory materials in the market with specifications/material data
sheet presenting same properties as designed refractory material, but should never
be used before physically tested to be suitable for the process.
Use of refractory materials without references will lead to un-scheduled shut-down!

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- Because operational season 2018 – 2019 has been more or less successful, most
of the refractory linings remain generally in good condition and deteriorating in
refractory lining has been local.
Sometimes in the future, refractory lining deteriorating may occur more rapidly,
when unit reach more operational age.

- By introducing alternative fuels (Biomass) to process, it is common that refractory

lining is exposed to temperature variations, alkalies, etc., which may cause
additional stress and there after some refractory lining deteriorate may start more
rapidly.

- Due mainly successful history of Unit-1 refractory lining, all future reparations
should follow original design and refractory materials, however some new
improvement designs and upgraded refractory materials should be taken into
consideration. We may assist to help you maintain long-life refractory lining in case
you trust our refractory know-how.

06.09.2019

Pasi Viemerö

Refractory Services, Inspections and Consulting

Broeye Finland Ky
pasi.viemero@broeye.com

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Company Telephone Email
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