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TECHNICAL REPORT ON

BOILER INSPECTION

Boiler-Takuma N1500 P

Custome Maysan State Sugar Enterprise


r Iraq / April 2010

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Contedo
1. CUSTOMER........................................................................................................................................................... 3
2. PLACE OF SERVICES / CONTACTS..................................................................................................................... 3
3. OBJECTIVE............................................................................................................................................................ 3
4. PERIOD OF INSPECTIONS................................................................................................................................... 3
5. ACCOMPLISHED INSPECTION............................................................................................................................ 3
6. HISTORIC OF THE BOILER................................................................................................................................... 3
7. DESCRIPTION OF SERVICES.............................................................................................................................. 3
8. ACCOMPLISHED INSPECTIONS.......................................................................................................................... 3
9. REFERENCE NORMS AND PROCEDURES......................................................................................................... 4
10. RESULTS............................................................................................................................................................. 4
10.1. ANALYSIS OF THE TECHNICAL DOCUMENTATION...................................................................................4
10.1.1. Handbook................................................................................................................................................ 4
10.1.2. Manual of Operation................................................................................................................................ 4
10.1.3. Quality Control of the Boiler Water........................................................................................................... 4
10.2. INTERNAL AND EXTERNAL INSPECTION................................................................................................... 5
10.2.1. Outlying................................................................................................................................................... 5
10.2.2. Steel Structures....................................................................................................................................... 6
10.2.3. Grate / Masonry / level Visor / Thermal Isolation.....................................................................................6
10.2.4. Fuel and Burn System............................................................................................................................. 8
10.2.5. Identification Plate................................................................................................................................. 10
10.3. VERIFICATION DISPOSITIVE OF CONTROL AND SAFETY OF THE BOILER..........................................11
10.3.1. Safety Valves......................................................................................................................................... 11
10.3.2. Instruments of Boiler control.................................................................................................................. 12
10.4. 10.4. INTERNal AND EXTERNAL INSPECTION, LOOKS AND MEASUREMENT OF THICKNESS...........13
10.4.1. Steam Drum........................................................................................................................................... 13
10.4.2. Water Drum........................................................................................................................................... 15
10.4.3. Superheater........................................................................................................................................... 17
10.4.4. Boiler Bank............................................................................................................................................ 18
10.4.5. Furnace Water Walls............................................................................................................................. 19
10.4.6. Economizers.......................................................................................................................................... 22
10.4.7. FDF - Forced Draft Fan......................................................................................................................... 23
10.4.8. IDF - Induced Draft Fan......................................................................................................................... 24
10.4.9. FAF - Primary Air Fans.......................................................................................................................... 24
10.4.10. Header of Economizer......................................................................................................................... 25
11. HYDROSTATIC TEST......................................................................................................................................... 25
12. RECOMMENDATIONS....................................................................................................................................... 26
13. CONCLUSION.................................................................................................................................................... 26
14. EQUIPMENTS USED IN THE INSPECTION ).................................................................................................... 26
15. RESPONSIBLE TECHNICians........................................................................................................................... 27
1. CUSTOMER
MAYSAN STATE SUGAR ENTERPRISE

2. PLACE OF SERVICES / CONTACTS


The services were performed at the Customer's facilities in Basrah, Iraq.

3. OBJECTIVE
The inspection consisted of internal and external exams of the Boiler and measurement of the pressure parts thickness
in order to evaluate the real physical conditions of the Boiler.

4. PERIOD OF INSPECTIONS
Beginning: 26/04/2010 End: 04/05/2010

5. ACCOMPLISHED INSPECTION
Operational evaluation of the boiler was accomplished.

6. HISTORIC OF THE BOILER


The equipment was manufactured in 1982 by TAKUMA under number of Order N-2625, with Capacity of Vapor
Production of 100.000 kg/h, Project Pressure (MWP) /Operation 36 / 30 kgf/cm-g respectively and overheated vapor
temperature of 380C.
In April 1982, the boilers normal operation started after its assembly conclusion and a period of all components tests
accomplished. Its operation proceeded respecting the project characteristics described in the identification plate.
The Boiler operated until the year of 2003, when it was placed in standby.
The Boiler stayed hibernated for 07 years and it is being inspected and maintained to return to its operation.

7. DESCRIPTION OF SERVICES
ANALYSIS OF THE TECHNICAL DOCUMENTATION.
Handbook

Manual of Operation

Quality Control of the Boiler Water.

8. ACCOMPLISHED INSPECTIONS
MEASUREMENT OF THICKNESS )
Parts subject to the internal Pressure (Drum/Tubes/Heater)

INTERNAL AND EXTERNAL LOOKS OF THE BOILER


Parts Subject to the Internal Pressure.
Grate / Masonry / level Visor / Thermal Isolation
Outlying
Metallic Structures:
Identification Plate

VERIFICATION OF THE BOILERS CONTROL AND SAFETY DEVICES


Safety valves
Boilers control instruments

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9. REFERENCE NORMS AND PROCEDURES
Norms
ASME Sec. I - ASME Boiler and Pressure Vessel Code Section I Rules for Construction of Power
Boilers
ASME Sec. II - ASME Boiler and Pressure Vessel Code Section II Part A (Ferrous Material
Specifications) and Part D (Properties)
ASME Sec. V - ASME Boiler and Pressure Vessel Code Section V - Nondestructive Examination

Procedures
PRO-DPI-004 - Thickness Measurement by Ultrasonic sound waves
PRO-DPI-054 - Hydrostatic Test
PRO-DPI-058 - Inspection of Water Tube Boiler

10. RESULTS

10.1. ANALYSIS OF THE TECHNICAL DOCUMENTATION

10.1.1. Handbook
- Code of the project and year of edition
- Specification of the materials
- Procedures used in the production, assembly, final inspection and determination of MWP
- Group of drawings
- Functional characteristics
- Data of safety's devices
- Year of production

Opinion There is The handbook of the Boiler with all the necessary information that approves the integrity of the
: Boiler and helps with the maintenance planning and repairs.

10.1.2. Manual of Operation


a) Procedures of departures and stops;
b) Procedures and operational parameters of routine;
c) Procedures for emergency situations;
d) General procedures of safety, health and preservation of the environment.

Opinion There is the Manual of Instructions with all the needed technical information and it is necessary that all
: the Boiler operators know the routines of this document.

10.1.3. Quality Control of the Boiler Water


Analysis: feeding Water of the boiler. Unit Manual of Instruction Found Deviation
pH (CALDEIRA) 9,4 ~ 11,0 - -
ALCALINIDADE TOTAL (CaCO3) ppm 0 - -
ALCALINIDADE HIDRXIDA (OH) ppm - - -
DUREZA (Ca CO3) ppm 0 - -
SLICA SOLVEL (HACH) ppm - - -
SLIDOS TOTAIS DISSOLVIDOS (25C) ppm - - -
SLIDOS SUSPENSOS ppm < 500 - -
CLORETOS (Cl) ppm < 80 - -
FERRO ppm - - -
FOSFATOS ( PO4) ppm < 0,2 - -
SULFITOS (SO3) ppm - - -
HIDRAZINA (N2H4) ppm 0,06 - -
QUELATOS ppm - - -
CONDUTIVIDADE S/cm2 - - -

Opinion We recommended the system of water treatment to be reviewed by a specialist company, since
: nowadays there is a more efficient technology. GE WATER and NALCO companies are leaders in this

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field.

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1.1. INTERNAL AND EXTERNAL INSPECTION

1.1.1. Outlying
a) Piping and Water Feeding Pump

Piping presents severe corrosion committing the Water feeding pump should be revised before entering in
structural integrity of the component operation.
b)

a) Control Valves and Manometer

Control valves should be revised before entering in


Damaged manometers should be substituted.
operation.

Opinion: All outlying for control and operation of the Boiler should be tested, maintained and substituted when
necessary.

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10.1.4. Steel Structures
a) Structure

Concrete Base of the boilers steel structure presents


Structures present good conservation state.
degree of acceptable waste.

Opinion Visually, the structure of the boiler presents satisfactory result for operation of the boiler.
:

10.1.5. Grate / Masonry / level Visor / Thermal Isolation


a) Grate of Masonry

Right side of the furnace in good state Left side of the furnace should be repaired

Opinion: Masonry of the Grate should be remodeled.

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b) Level Visor

Level Visor should be tested and maintained Magnetic Transmitter of Level should be tested and maintained
before the operation of the boiler. before the operation of the boiler.

Opinion: All control and operational components of the Boiler should be tested and maintained.

c) Thermal Isolation

Exit of gases and left side of the Boiler show damaged Roof of the boiler furnace and tube risers show damaged
isolation. isolation.

Opinion Visually, the isolation of the boiler is damaged in several points. Repairs should be accomplished to avoid
: accidents with the operators and for a better thermal efficiency of the Boiler.

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10.1.6. Fuel and Burn System

a) Oil Reservoir

Visually, the reservoirs present a satisfactory result; when Regulators of oil line flow should be maintained and
possible, they should be inspected internally for leak installed.
verification.

b) Oil Pumps

Oil pumps should be tested and every system should


System of oil filter should be maintained.
pass through cleaning flushing..

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c) Oil Heaters

Oil Heaters should be cleaned and inspected Oil Heaters should be cleaned and inspected

Opinion Based on the equipments Report, the cleaning of the heater internal parts and a visual inspection are
: necessary to verify the condition of the equipment and the need of the No Destructive Test.

d) Burners

There are four burner modules with their peripherical parts


All the Burners should simulate the system of fuel cut in
disassembled. The necessary maintenance should be
the lack of fire, mainly the ones that work with gas.
performed.

Opinion All the internal components of the Burners should be disassembled: valves, o rings, holes. They should
: be inspected and tested on bench.

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10.1.7. Identification Plate

Manufacturer : TAKUMA
Boiler/ Model : N 1500P
Year of production : 1982
Registration number : N 2625
Steam production : 100.000 kg/h
Pressure of Operation : 30,0 kgf/cm
Max Working Pressure : 36,0 kgf/cm
Pressure of Hydrostatic Test : 54,0 kgf/cm
Heating surface : 1158m
Temperature of the overheated steam : 380C
Edition / Addenda of the code : 1982
Project code : ASME I
Addressee : Misan State Sugar Enterprise

LAYOUT OF THE PLATES

Opinion Identification plate in place of easy access and visualization.


:

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10.2. VERIFICATION DISPOSITIVE OF CONTROL AND SAFETY OF THE BOILER
10.2.1. Safety Valves

SAFETY VALVE OF SUPERHEATER


Producer : NAKAKITA
Model : NS 255 FY
Entry diameter (mm) : 57
Exit diameter (mm) : 71
Adjustment pressure (Kgf/cm 2) : 31,0
Opening pressure (Kgf/cm 2) : 31,0
TAG : PSV 7
Series number : -

SAFETY VALVE 01 OF STEAM DRUN


Producer : :
NAKAKITA
Model : : NS 255 FY
Entry diameter (mm) : 57
Exit diameter (mm) : 71
Adjustment pressure (Kgf/cm 2) : 33,0
Opening pressure (Kgf/cm 2) : 33,0
TAG : PSV 8
Series number : 82F747

SAFETY VALVE 02 OF STEAM DRUN


Producer : :
NAKAKITA
Model : : NS 255 FY
Entry diameter (mm) : 57
Exit diameter (mm) : 71
Adjustment pressure (Kgf/cm 2) : 36,0
Opening pressure (Kgf/cm 2) : 36,0
TAG : PSV 9
Series number : 82F746-1

Opinion All of the flanged safety valves installed in the Boiler should be dismounted, inspected and tested on
: bench and, regarding the welded valves, calibrated.

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10.2.2. Instruments of Boiler control

a) Boiler Panel of Command

Visually, the panel and their instruments present good Every instrument of the Boiler should be tested before the
conservation state. Boiler enters in operation.

b) Boiler External panel of Command

Burners Panel of command Pressure and temperature Indicator and controller

Opinion All instruments of the Boiler should be dismounted, inspected, tested and calibrated.
:

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10.3. 10.4. INTERNAL AND EXTERNAL INSPECTION, LOOKS AND MEASUREMENT OF THICKNESS

10.3.1. Steam Drum


Table 1- Steam Drum (Measurement of Thickness mm)
1 Point 2 Point 3 Point 4 Point 5 Point 6 Point
Body
Area without hole 42,32 41,25 41,05 42,37 x x
Holed area 62,25 62,39 62,39 62,30 x x
Right lid 0 = 39,11 90 = 42,04 180 = 43,10 270 x
Left lid 0 = 42,17 90 =42,53 180 = 44,14 270 x

Quota Dimension 50,8 Dimension 76,2


A 70,0 mm x mm
B 130,0 mm x mm
C 180,0 mm x mm
D 1.800 mm
E 5.800 mm
F 130,0 mm
G 400,0 mm
H 22,0 mm

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a) Steam Drum Visual Inspection

There are several tubes of the Bank disabled due to a flaw Visually, an excessive accumulation of a white colored
during the operation of the Boiler. incrustation was observed.

b) Internal Steam Drum

The internal parts of steam sifter should be disassembled


Internal parts of the drum present a widespread
and cleaned to guarantee the efficiency and the operation
incrustation of water and steam phase.
of the equipment.

Opinion: All of the internal elements should be dismounted and cleaned to guarantee the efficiency and the
:
operation of the equipment; it is advisable to accomplish the Hydrocleaning of the Boiler internal parts.

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10.3.2. Water Drum
Table 2- Water Drum (Measurement of Thickness mm)
1 Point 2 Point 3 Point 4 Point 5 Point 6 Point
Body
Area without hole 42,32 40,81 41,96 41,88 x x
Holed area 41,81 41,71 41,64 42,51 x x
Right lid 0 = 35,88 90 = 35,36 180 = 35,80 270 x
Left lid 0 = 35,76 90 =35,65 180 = 35,58 270 x

Quota Dimension 50,8 Dimension 76,2


A 70,0 mm x mm
B 130,0 mm x mm
C 180,0 mm x mm
D 1.228 mm
E 5.800 mm
F 130,0 mm
G 400,0 mm
H 22,0 mm

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a) Water Drum Internal Look

Visually, an excessive accumulation of white colored There are several tubes of the Bank disabled due to a
incrustation was observed.. flaw during the operation of the Boiler.

b) Water Drum Internal Look

Heater Tube was removed for substitution of the Boiler External side of the Drum Water where the Bank tubes
Bank tubes. were being substituted.

Opinion Visually, an excessive accumulation of white colored incrustation was observed. Analysis should be
: accomplished for correction of the water treatment of the Boiler.
The initiated repairs in the Boiler should be finished.

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c) Tubes of the Superheater

10.3.3. Superheater
Table 3- Superheater (Measurement of Thickness mm)
Point n 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
A x x x x x x x x x x x x x x x
B x x x x x x x x x x x x x x x

Point n 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
A x x x x x x x x x x x x x x x
B x x x x x x x x x x x x x x x
Legend:
A= Straight C= Straight E= Straight G= Straight
B= Curved D= Curved F= Curved H= Curved
Ext. 50,8 mm

a)

Original drawing of the super heater. It was not


Visual of the superheater from within the furnace of the Boiler. possible to access the equipment for measurement
of thickness.

Opinion Visually, relevant deformations in the component were not observed. An access to the tubes should be
: provided for thickness measurement.

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Table 4- Boiler Bank (Measurement of Thickness mm)

10.3.4. Boiler Bank


a)

Point n 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
A 3,96 4,17 4,49 4,42 3,96 4,33 4,37 4,29 4,30 4,29 4,00 4,23 3,84 3,99 4,06
B x x x x x x x x x x x x x x x

Point n 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
A x x x x x x x x x x x x x x x
B x x x x x x x x x x x x x x x
Legend:
A= Straight C= Straight E= Straight G= Straight
B= Curved D= Curved F= Curved H= Curved
Ext. 50, 8 mm

b) Boiler Bank welding

Visually, the welds present deficiency; hydrostatic tests


Tubes of the Boiler Bank - the ferrules of ascending tubes should be accomplished for welds approval.
were substituted and welded.

c) Substitution of Boiler Bank tubes

Area where Boiler Bank tubes were substituted. Closing row of Boiler Bank should be reconstituted (17

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Tubes)

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d) Substitution of Boiler Bank tubes

90% of the Boiler Bank tubes present Incrustation in their


New tubes visually present lack of tube expansion.
internal part.

Opinion As commented in the subtitle 10.4.1 of this report, the tubes of the Boiler Bank should be
: Hydrocleaned; the structural condition of these tubes should be evaluated and subsequently repaired.
The initiated repairs in the Boiler should be finished. The measurement of thickness presented
satisfactory results.

10.3.5. Furnace Water Walls


Table 5- Furnace (Measurement of Thickness mm)
Point n 1 2 3 4 5 6 7 08 09 10 11 12 13 14 15
PLE. Re. 1 4,22 4,11 4,15 4,40 4,23 4,48 4,12 4,49 4,06 3,95 3,91 4,16 4,37 4,03 3,85
PLT. Re. 1 4,07 4,27 4,08 4,32 3,95 3,83 4,18 4,00 4,09 4,13 4,09 3,90 4,39 4,43 4,02
PLD. Re. 1 4,03 4,47 4,26 4,45 4,15 4,01 3,86 4,05 3,88 3,73 4,08 4,10 3,92 3,82 3,71
PLF. Re. 1 4,14 3,95 4,02 4,02 4,18 4,29 3,98 4,27 3,92 4,17 4,28 4,52 4,47 4,61 4,01
Legend:
PLE= Left Side Wall 1= Elevation Next to Inferior Header Furnace
PLD= Right Side Wall 2= Elevation 3 meters
PLT= Bottom Side Wall 3= Elevation 7 meters
PLF= Front Side Wall 4= Elevation 12 meters

PLE= Left Side Wall


Units 56 Tubes 76,2 mm
PLD= Right Side Wall
Units 56 Tubes 76,2 mm
PLT= Bottom Side Wall
Units 53 Tubes 76,2 mm
PLF= Front Side Wall
Units 53Tubes 76,2 mm

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a) Furnace Water Walls

Inspection was accomplished in areas that suffer wear and Measurement was accomplished in 100% of the
tear by abrasion and erosion.. prepared tubes. Samples from15 points per Furnace wall
were collected for the report.

b) Furnace Water Walls

Tube in the center of the front wall is disabled; a needed Visually, the furnace presents good conservation state,
repair should be accomplished. the accomplishment of routine maintenance is necessary.

Opinion The initiated repairs in the Boiler should be finished, measurement of thickness presented satisfactory
: results.

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c) Thermal Treatment of the Furnaces Left Side

At the Furnaces Left Side, the substitution of the wall Area where approximately 15 tubes were substituted.
tubes was observed and they were welded directly to the
collector. The code ASME informs the need of thermal
treatment for thicknesses larger than 19,00 mm. The
Header is 25,4 mm.

d) Furnaces Left Side Repairs

Furnaces Left Side area, where repair should be Furnaces Left Side area, where repairs in the Boiler
accomplished in 12 (Twelve) tubes 76, 2 with should be concluded in 10 (ten) tubes 76, 2 with
approximately 500, 0 mm and 1300, 0 mm length. approximately 2800, 0 mm length.

Opinion Planning should be accomplished for the execution of repairs and thermal treatment, where applicable.
:
The initiated repairs in the Boiler should be finished, measurement of thickness presented satisfactory
results.

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10.3.6. Economizers

Table 6- Economizer (Measurement of Thickness mm)


Left
Point n 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
A x x x x x x x x x x x x x x x
B 2,42 3,58 2,92 2,49 2,49 3,21 3,05 3,05 4,67 2,42 3,58 2,92 2,49 2,49 3,21
Right
Point n 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
A 3,93 3,03 2,87 3,35 3,08 3,05 3,93 3,03 3,93 3,03 2,87 3,93 3,03 2,87 3,35
B x x x x x x x x x x x x x x x
Legenda:
A= Straight C= Straight E= Straight G= Straight
B= Curved D= Curved F= Curved H= Curved

a) Economizer

Points of the Economizers Left side, where thickness Points of the Economizers Right side, where thickness
was measured. was measured.

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b) Economizer

Tube disabled during operation of the Boiler. Necessary Welds accomplished in the tubes should be
repair should be accomplished. hydrostatically tested for approval.

Opinion The initiated repairs in the Boiler should be finished; measurement of thickness presented satisfactory
: results.
The welds accomplished in the Boiler should be hydrostatically tested for approval.

10.3.7. FDF - Forced Draft Fan


a) FDF - Forced Draft Fan

Fan internal parts should be disassembled, cleaned, Reducer and Turbine should be inspected and a
inspected and balanced.. necessary maintenance should be done.

Opinion: Equipments should be maintained and tested before setting the Boiler in operation.
:

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10.3.8. IDF - Induced Draft Fan
a) FDF - Forced Draft Fan

Fan internal parts should be disassembled, cleaned, Electric motor should be inspected and necessary
inspected and balanced. maintenance should be done before reinstallation.

10.3.9. FAF - Primary Air Fans


a) FAF - Primary Air Fans

Fan internal parts should be disassembled, cleaned, Reducer and Turbine should be inspected and necessary
inspected and balanced. maintenance should be done.

Opinion Equipments should be maintained and tested before setting the Boiler in operation.
:

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10.3.10. Header of Economizer

Table 7 Header of Economizer (mm)


Point 1 2 3
Header of Entrance 12,00 11,74 12,11
Header of Exit 11,23 12,24 11,92
Quotes Tube Ext. = 50,8 mm
A
B
A Step= 103,0 mm
B Ext. = 254,0 mm

a) Header of Economizer

Area where the measurement of thickness was The repair was not foreseen in the project. It should be
accomplished. approved after Hydrostatic test.

Opinion The initiated repairs in the Boiler should be finished, measurement of thickness presented satisfactory
: results.
The welds accomplished in the Boiler should be Hydrostatically tested for approval.

11. HYDROSTATIC TEST

Opinion The hydrostatic test should be accomplished after the conclusion of the Boilers maintenance with the
: value of 1,5 x MWP for detection of possible flaws in the Boilers tubes, where the meticulous inspection
of the equipment was performed.
The welds accomplished in the Boiler should be Hydrostatically tested to be approved.

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12. RECOMMENDATIONS
1.1. We recommended the system of water treatment to be reviewed by a specialist company, since nowadays there is
a more efficient technology. Companies such as GE WATER and NALCO are leaders in this sector. See subject
10.1.3, 10.4.1 and 10.4.2 of this report.
1.2. All outlying for control and operation of the Boiler should be tested and maintained. See subject 10.2.1, 10.2.3,
10.2.4 and 10.3.2 of this report.
1.3. All of the flanged safety valves installed in the Boiler should be dismounted, inspected and tested on bench and,
regarding the welded valves, they should be calibrated. See subject 10.3.1 of this report.
1.4. All of the internal elements should be dismounted and cleaned to guarantee the efficiency and operation of the
equipment. It is advisable to accomplish Hydrocleaning of the Boiler internal parts. See subject 10.4.1 and 10.4.2 of
this report.
1.5. For execution of repair services in the Boiler, appropriate welding procedure and qualified welders should be
adopted. The following documentation should be requested to the company that will execute the services: Welding
Procedure Specification (WPS), Procedure Qualification Record (PQR) and Welding Operator Performance
Qualification (WPQ)
1.6. After the conclusion of the foreseen alterations, the performance of the Boiler should be accompanied and the
occurrences that can happen should be monitored.

13. CONCLUSION
1.1. The Boiler should be submitted to welding interventions and expansion of mandrel. These services should be
accomplished by the Qualified Supplier. See subject 10.4.4 and 10.4.5
1.2. The recommendations mentioned in the item 12 of this report should be totally assisted.
1.3. Obs. The minimum wall thicknesses of the pressure parts are satisfactory and approved for the defined operation
conditions in the project adopted for construction of the equipment.

14. EQUIPMENTS USED IN THE INSPECTION )


Meter of thickness : Krautkramer DMS2
Identification Welding n 1668

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15. RESPONSIBLE TECHNICIANS

Anderson Wander Pupin


Inspetor da Qualidade
CREA N. 5061589024
SNQC/END. 06245

Roque Clovis Giacomassi Junior


Inspetor da Qualidade
IS-4167-N1

Carlos Henrique Dalmazo


Profissional Habilitado
CREA N.: 0400.45666.7

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