January 23, 2010.

REPORT ON 135 TPH BOILER INSPECTION AT SHYAM DRI LIMITED

UNIT-II THIS IS THE SECOND VISIT MADE FOR STAGE INSPECTION OF BOILER UNDER ERECTION. 01. A WELDING GAP IS FOUND IN EITHER SIDE OF THE FRONT WATER WALL PANEL. 02. IN LEFT SIDE WATER WALL PANEL 1 TO PANEL 2 WELDING IS IN PROGRESS. 03. BED CIOL TOP HEADER TO HEADER WELDING IS IN PROGRESS. 04. TEMPORARY SUPPORT HAS BEEN REMOVED AND PERMANENT SUPPORT SHALL BE PROVIDED TO BED COIL TOP, BOTTOM AND WATER WALL TOP HEADER. 05. DOWN COMER AND RISER ERCTION IS IN PROGRESS. 06. SECONDARY SUPER HEATER COIL ERECTION IS UNDER PROGRESS. 07. ECONOMISER IS YET TO BE REALIGNED.MISALIGNED WILL LEAD TO EROSION OF ECONOMISER TUBES. 08. BENDING OF THE LEFT SIDE WATER WALL PANEL IS FOUND.THIS SHALL BE RECTIFIED. 09. TRANSIT DAMEGE IS FOUND IN THE LEFT WATER WALL HEADER STUB. THE DAMEGE HAS BEEN RECTIFIED. 10. BUNKER ERCTION IS IN PROGRESS. 11. PLATFORM APPROACH FOR APH AND ECONOMISER SHOULD BE PROVIDED. 12. BENDING THREE OUTER BED COIL IS FOUND.THIS SHALL BE RECTIFIED. 13. APH I AND APH II ARE LIFTED. 14. ESP COLUMNS ARE ERECTED. 15. ESP CASING TO STIFFENER WELDING IS IN PROGRESS. 16. FD FAN FOUNDATION YET TO BE STARTED.

BY, A RAMACHANDRAN, 23.01.2010. VENUS ENERGY AUDIT SYSTEM. FOR , SYAM DRI POWER LTD, SAMBALPUR.

Photo 1- Bending of the left side water wall panel is found. This shall be rectified.

Photo 2- Tube to tube (11th) full welding is pending. It shall be checked for completion of welding. (Front water wall panel I ).

Photo 3- Tube to tube (19th) full welding is pending. It shall be checked for completion of welding. (Front water wall panel I ).

Photo 4- Front side water wall panel to panel full welding is pending. It shall be checked for completion of welding.

Photo 5. Welding has to be competed in the front water wall panel to right side water wall panel.

Photo 6- Additional piece shall be added after cutting the water wall tube certain length.

Photo 7-. Tube offset is found in the left water wall panel. This shall be rectified.

Photo 8-.panel to panel shall be full welded instead of stitch welding.

Photo9- Welding has to be competed in the rear water wall panel to panel. This shall be full welded.

Photo 10- Tube to tube full welding is pending. It shall be checked for completion of welding. (Right water wall panel )

Photo11- The transit damage is found in the level indicator pipe. This shall be rectified.

Photo 12. In bunker all the stiffening beams shall be terminated to vertical columns. Unclosed ties do not meet the design requirement.

Photo 13- Additional piece shall be added in this water wall tube.

Photo14- . Economizer is yet to be realigned. Misaligned will lead to erosion of economizer tubes.

Photo 15-.Economiser casing to bellow shall be full welded instead of stitch weld.

Photo 16- The transit damage is found in the outer bed coil. This shall be rectified.

Photo 17- The transit damage is found in the two outer bed coils. This shall be rectified.

Photo 18- The transit damage is found in the left side water wall bottom header stub. This shall be rectified.

Photo 19- Plastic end caps shall not be removed until supply pipes are erected. Otherwise it may lead to accumulation of foreign materials like weld rod etc.

Photo 20-. Secondary super heater coil is yet to be realigned. Misaligned will lead to erosion of super heater tubes.

Photo 21- Slag cleaning is must for all welds to inspect the weld.

Photo 22-. Stiffener shall be provided to the bend duct.( In boiler unit I , FD to APH).