Modification and Refurbishment Report

Date: 10/03/2015 Job No.: 1505025

Unit: 503-504-505-506 Client: Ansaldo Thomassen

INTRODUCTION

Remazel Engineering has been asked to assist and supervise the activities for the refurbishment
and modification of n4 diverters.
The units were stored for more than 8 years without being used and need now to be restored and
renewed before the installation on site.

In origin the units were designed for Combined cycle but since they will now be used for a simple
cycle some modification are needed since many item are not be used anymore and do not need to
be reinstated.

The activities were performed in local workshop in Abu Dhabi, Remazel were in charge to supervise
the activities of the local supplier and to design the modifications of the unit.

Components not used and eliminated:

- Drive tube
- Blade connections
- Blade
- Landing bar
- Piping and fan for the air barrier
- Guillotine

Due to the above, some modifications are necessary:

- Closing of the drive tube passages
- Modification of the landing bar area and insulation modification
- Design and fabrication of a dedicated blanking plate in place of the guillotine
- Foundation adjustments due to the missing of the guillotine

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DESCRIPTION OF THE ACTIVITIES

ITEM DESCRIPTION
Removing the blade and drive tube it has been necessary close the holes for shaft
passage on the diverter structure.
For this reason additional internal and external plates have been installed and insulation
has been inserted to avoid heat exchange from internal to external side.

Below some pictures showing the modification:

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The internal connections for the blade have been removed and replaced with cladding.
2
This will avoid thermal bridges due to unused blade connections.

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To avoid further thermal bridges from landing bar area and due to the fact that the blade
is no more used, the landing bar has been removed on both sides, Bypass and Boiler.
3
Insulation and cladding have been added.
Below some pictures self-explanatory.

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Unused air barrier system has been removed and the inlet has been sealed with welded
plates, insulation added to avoid heat dissipation.

Guillotine will not be installed cause not used in the simple cycle.
To close the flange on Boiler side a dedicated and reinforced blanking plate has been
designed by Remazel Engineering.
5 For logistic reasons the blanking plate has been designed in 2 sections to be connected
and welded on site.
Below some pictures showing the first phase of the production from ATH local supplier in
Abu Dhabi.

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The diverters have been completely blasted and painted internally and externally.
The blasting and painting activities have been performed by ATH local supplier according
to ATH procedures.
Some steel plates were found with extended and deep corrosion and have been renewed.
6

The ceramic fiber insulation has been restored according to original design and original
thickness.
Only a 1mm glass fiber cloth has been added.

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All the pressure tapping points have been sealed internally and threaded plugs mounted
on the external side.
For each diverter a single tapping point has been left for possible transducers to the
mounted on site.

Foundations have been blasted and repainted by local supplier according to ATH
procedures.
7 Adjustments made in order to correctly fit with the diverter without guillotine (spacers
added).
Interfaces with ground remain without any variations from original design.

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Attached to this report:

- 1505025-DW-D-200 Drawing showing the modification on landing bar
8 - 1505025-DW-D-320 Drawing of the blanking plate
- 1505025-DW-D-600 Drawing of the foundation adjustment

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