The document provides an inspection report of equipment at an NA plant during an outage. It inspects Lamont boilers B-101 A/H-105 A and B-101 A/H-105 B using visual inspection, dye penetrant testing, ultrasonic testing, and metallography. Observations found weld seams, nozzles, coils, and shells to be satisfactory. Minor issues like a damaged basket mesh were addressed. Thickness monitoring found readings within design limits. Hardness testing also produced acceptable results. The CDM NH3 evaporator line was also inspected and a small through-wall crack was discovered and repaired by replacement. Additional miscellaneous inspection work was also carried out.
This Quality Plan and Inspection and Test Plan is prepared to assure the safe operational and to provide the guidance controlling Quality, Inspection and Test activities of ready mix concrete supply, including its raw material for Betara Complex development Project, Jambi, Indonesia.
A Comparative Study on Gland Packing Testing for Fugitive Emissions based on API Standards only. This was primarily done for testing of FE Gland Packings for low Temperature applications.
Recurring inspection means inspection of the material at regular intervals like every month, every year etc. The system can automatically create inspection lots at predefined intervals for selected batch materials. You can plan such inspections by having the system monitor the date for a recurring inspection. Recurring inspections are triggered by a report that you can execute manually or that the system can execute automatically (provided it has been planned as a background job). When recurring inspections are triggered automatically, the background job executes the report, which in turn selects the batches and creates the inspection lots according to your processing parameters. Recurring inspection process widely used in Process industries like Pharmaceutical, Chemical and Food industries
This Quality Plan and Inspection and Test Plan is prepared to assure the safe operational and to provide the guidance controlling Quality, Inspection and Test activities of ready mix concrete supply, including its raw material for Betara Complex development Project, Jambi, Indonesia.
A Comparative Study on Gland Packing Testing for Fugitive Emissions based on API Standards only. This was primarily done for testing of FE Gland Packings for low Temperature applications.
Recurring inspection means inspection of the material at regular intervals like every month, every year etc. The system can automatically create inspection lots at predefined intervals for selected batch materials. You can plan such inspections by having the system monitor the date for a recurring inspection. Recurring inspections are triggered by a report that you can execute manually or that the system can execute automatically (provided it has been planned as a background job). When recurring inspections are triggered automatically, the background job executes the report, which in turn selects the batches and creates the inspection lots according to your processing parameters. Recurring inspection process widely used in Process industries like Pharmaceutical, Chemical and Food industries
Discussion of Regulatory issues in closing a chemical manufacturing facility. Presented the Alliance for Chemical Safety July 9, 2014 by Willard Vaughan, PE CIH
The word “Pellet” has been used to describe a variety of systematically produced, geometrically defined agglomerates obtained from diverse starting materials utilizing different processing conditions. Pellets range in size, typically, between 0.5 – 1.5 mm, though other sizes could be prepared. Pellets are for pharmaceutical purposes and are produced primarily for the purpose of oral controlled-release dosage forms having gastro resistant or sustained-release properties or the capability of site-specific drug delivery.
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This material provides the basic of design, operation and maintenance so that you can use this as guide line to operation, to inspect your boiler. Hope this will be benefit you.
Overhauling of a machine is defined as a process of general maintenance performed on a machine or other industrial equipment. The goal of overhauling is to keep the system in serviceable condition. Regular checks can prevent all kinds of critical damage.
Overhauling is the effective maintenance program should be such that the basic objective is achieved with minimum possible expenditure. The availability of turbine, and mainly the operating reliability, depends on the satisfactory operation of its control, protection of ancillary equipment such as pumps etc. The study deals with the tests and maintenance necessary to ensure good operating reliability for the turbine. The Turbine Overhauling work is generally done during a planned shutdown. An overhauling is a detailed inspection and overhaul of the entire gas turbine set including the turbine casing, rotor, seals, and bearings; the generator; and auxiliaries such as the gear, couplings, lubrication system, and controls.
Similar to Inspection Report during Plant Outage @ NA Plant (20)
1. Prepared By: Khurram Fayyaz
Inspection Report during Plant Outage @ NA Plant
Equipment: B-101 A/H-105 A (Lamont Boiler)
Inspection Technique: VI, DPT, UT and Metallography
INSPECTION SCOPE:
· VI and DPT of Burner Head.
· DPT of Weld Seams of Shroud.
· DPT of Welding Seams of Catalyst Basket.
· Hardness Measurement.
· Visual Inspection of Coils.
· Thickness Monitoring of Coils.
· Inspection of Shell, Nozzles and coils welding joints.
· Metallography of Shell
OBSERVATIONS:
Inspection of B-101 A/H-105 A (Lamont Boiler) was carried out and observations are as follows:-
· DPT of Welding Seams of Burner head was carried out and no cracks/pinholes were observed
· DPT of Welding seams of Catalyst basket was carried out and found satisfactory
· DPT of Burner head external and internal nozzles was carried out and found satisfactory
· DPT of Weld Seams of Shroud was carried out and found satisfactory
· Mesh of Basket found damaged at one point. New Mesh Installed.
· Thickness Monitoring of coils was carried out;
Max: 3.7 mm, Min: 3.4 mm, Design: 3.6 mm
· Hardness Testing of shell was carried out and all the values are in acceptable range;
Max: 175 HB, Min: 150 HB
Hardness Values in TA-2015: Max: 190 HB, Min: 135 HB
· 70% Thickness monitoring of line included fittings from H-105 to H-112 has been carried out and found
satisfactory.
· Max: 6.7 mm, Min: 6.1 mm, Design: 4.2 mm
· Metallography activity for La-Mont Boiler on H-105 A/B has been completed, 01 Replica from H-105 A on shell
was taken. Report is awaited.
2. Prepared By: Khurram Fayyaz
Inspection Report during Plant Outage @ NA Plant
PICTORIAL
DPT of nozzle of Burner head
DPT of T-Joints of basket
3. Prepared By: Khurram Fayyaz
Inspection Report during Plant Outage @ NA Plant
PICTORIAL
Mesh of basket found damaged
Thickness Monitoring of Coils
4. Prepared By: Khurram Fayyaz
Inspection Report during Plant Outage @ NA Plant
Equipment: B-101 A/H-105 B (Lamont Boiler)
Inspection Technique: VI, DPT, UT and Metallography
INSPECTION SCOPE:
· VI and DPT of Burner Head.
· DPT of Weld Seams of Shroud.
· DPT of Welding Seams of Catalyst Basket.
· Hardness Measurement.
· Visual Inspection of Coils.
· Thickness Monitoring of Coils.
· Inspection of Shell, Nozzles and coils welding joints.
· Metallography of Shell
OBSERVATIONS:
Inspection of B-101 A/H-105 B (Lamont Boiler) was carried out and observations are as follows:-
· DPT of Welding Seams of Burner head was carried out and no cracks/pinholes were observed
· DPT of Welding seams of Catalyst basket was carried out and found satisfactory
· DPT of Burner head external and internal nozzles was carried out and found satisfactory
· DPT of Weld Seams of Shroud was carried out and found satisfactory
· Mesh of Basket found satisfactory.
· Thickness Monitoring of coils was carried out;
Max: 3.8 mm, Min: 3.4 mm Design: 3.6 mm
· Hardness Testing of shell was carried out and all the values are in acceptable range;
Max: 164 HB, Min: 150 HB
Hardness Values in TA-2015: Max: 243 HB, Min: 140 HB
· 70% Thickness monitoring of line included fittings from H-105 to H-112 has been carried out and found
satisfactory.
Max: 6.4 mm, Min: 5.9 mm, Design: 4.2 mm
· Metallography activity for La-Mont Boiler on H-105 A/B has been completed, 03 Replicas from H-105 B were
taken (02 Replica from Shell near Cracks & 01 Replica from Flanged Portion near Crack). Reports are awaited.
· The existing crack has been checked and measured by Inspection team and No increase in crack size (Length)
observed.
5. Prepared By: Khurram Fayyaz
Inspection Report during Plant Outage @ NA Plant
PICTORIAL
DPT of T-Joints of Basket
DPT of T-Joints of burner head
6. Prepared By: Khurram Fayyaz
Inspection Report during Plant Outage @ NA Plant
PICTORIAL
DPT of nozzle of Burner head
DPT of Crack on shell after placing burner head back
7. Prepared By: Khurram Fayyaz
Inspection Report during Plant Outage @ NA Plant
Equipment: CDM NH3 Evaporator line
Inspection Technique: VI, DPT, UT
INSPECTION SCOPE:
· VI and DPT of Line
· UT of Line
OBSERVATIONS:
Inspection of CDM NH3 Evaporator line was carried out and observations are as follows:-
· Thickness Monitoring of CDM NH3 Evaporator was carried out and found satisfactory
Design: 5.54 mm, Min: 5.5 mm, Max: 5.7 mm
· DPT of complete line was carried out. 01 location through hole crack observed approximately 08 to 10 mm length.
Needs to be repair.
Work Done:
· After grinding DPT was performed again and branches of cracks were found due to which CDM ammonia vaporizer
affected portion has been replaced with a new one.
· DPT after Welding activity was carried out by Inspection and results found satisfactory.
Crack view after DPT
8. Prepared By: Khurram Fayyaz
Inspection Report during Plant Outage @ NA Plant
Miscellaneous Jobs:
1. Internal Inspection of Filter L-101 Air Duct was carried out.
o Cleaning required before Box-Up.
o Overall condition found satisfactory.
2. DPT after welding of STG Joints was carried out and found satisfactory.
3. PWHT of 09 Joints of STG area was carried out. Job Completed.
4. RT of 09 Joints of STG area has been carried out in night shift. Result found satisfactory.