FOSTER WHEELER MEXICANA, S. A. DE C. V.

INGENIERÍA Y FABRICACIÓN DE ESTRUCTURAS-EQUIPO DE PROCESO-EQUIPO ESPECIALIZADO

PARA LA INDUSTRIA QUÍMICA, PETROQUÍMICA Y METAL-MECÁNICA

Rengen Permanent Plugging Procedure (Rengen Mud Drum). REV 1

1. Check the NCR for the corrective action. Inform Authorised Inspector of the repair procedure. Inform
Babcock and Wilcox of the start of the repair process.
2. Identify the additional hole in question (Q.A & Q.C to verify (mark clearly on the Drum)
3. OPI preparation. (Operation Planning Instructions.) Make a detailed repair procedure that has key
inspection points. Customer, Client ASME.
4. Set the drum up level + square on the machine table.
5. Rotate the drum until the extra hole has been positioned at 0°.
6. For levelling purposes insert a machined plug into the hole that has a diameter of plus .001”-.002”
more than actual extra hole diameter, this will help align the hole perpendicular
7. Check the drum for level and square, using a precision level
8. Secure the drum to ensure it’s solidly fixed.
9. Using a reamer or end mill, enlarge the hole to +.005” above the serration diameter. See Sketch1
10. Check the diameter and record the dimension.
11. Clean the hole using thinners to eliminate all contamination.
12. Select a material the same as the drum material SA 516 Gr. 70 with traceable MTR’s (Inspected and
verify by Q.A and Q.C).
13. Machine the plug to the sketch provided (Sketched 2)
14. Preheat locally the extra hole to 250°F min. Check with calibrated Pyrometer (Q.A and Q.C).
15. Clean plug and insert into the hole (See sketch 3).
16. TIG tack welding around perimeter on the plug. WPS Number GT-11-T-33 (see attached)
17. Dye Check TIG tack welds (Q.A and Q.C).
18. Clean liquid penetrant.
19. Again preheat locally the hole area and plug to 250°F.
20. Using the TIG process, weld the plug cavity until complete above the thickness of drum. See sketch 4
21. Turn the drum over and back gouge the inside of the hole until breaching the initial deposited weld
material. See sketch 5
22. Dye check excavated area.
23. Clean and grind the excavated area of penetrant.
24. Preheat area to 250°F. check with calibrated pyrometer.
25. Weld cavity beyond thickness of drum. See sketch 6
26. Allow the plug to cool.
27. Apply liquid penetrant and check for indications.
28. Clean liquid penetrant from inside weld surface.
29. Grind both sides of plug to produce a blended surface with the form of the drum.
30. X-Ray the plug 100% including UT 100%
31. Attach the resistance PWHT Coils to cover the hole in question, wrap accordingly with fiber.
32. Using accurately machined bronze plugs, plug all affected holes in the local area to the repair,
minimizing any possibility of distortion. The bronze plugs will absorb the excess heat minimizing
ovality problems
33. Start the PWHT process and monitor using the chart provided. See attached PWHT chart.
34. Finish the PWHT process and check the graph to ensure rise, hold, fall temperatures where maintained
35. Remove the bronze plugs and check surrounding tubehole diameters’ Check for any ovality and
record.
36. Perform a final UT on the plugged hole.
37. Present the repair with all accompanying information to the ASME Inspector.
38. Inform our client Babcock and Wilcox of the completion of the repair.
39. Final inspection by FWM QA and QC
40. Add all information into the final dossier, charts, preheat temperatures, ect.
41. Sign off customer witness and Babcock and Wilcox
42. Close out the NCR
43. Remove the red reject sticker.
 FOSTER WHEELER MEXICANA, S.A. DE C.V.
GERENCIA DE ASEGURAMIENTO DE CALIDAD
QUALITY ASSURANCE MANAGEMENT

GRAFICA DE TRATAMIENTO TERMICO

GRAPHIC OF HEAT TREATMENT

N° ORDEN DE PRODUCCION N°. DE PROCESO N°. DE FASE DESCRIPCION HOJA: 1

JOB ORDER PROCESS N°. PHASE N°. DESCRIPTION SHEET

F-416-2 (356 G) 036/19 ------- STRESS RELIEF DE: 1

FM120-124 LH BOILER (RENGEN) OF

DESCRIPCION DE LA PIEZA O ENSAMBLE.: REPARACION EN BARRENO DOMO INFERIOR

DESCRIPTION OF PART OR ASSEMBLY ( REPARATION IN HOLE OF LOWER DRUM 24" )

ºc
1000
900
+15ºC MAX (+59ºF MAX)
800 - 15ºC MIN (- 59ºFMIN)

700 615º C (1139ºF) + 15 MINUTOS

-0 MINUTOS
600 1HORA
500 100ºC/H.MAX 100ºC/H. MAX.
400
300 F AIRE CALMADO
R
200 E STILL AIR
100 E
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 HRS.

POSICIONAMIENTO DRUM EN EL HORNO Y DE LOS TERMOPARES --------

POSITION ON THE FURNACE AND TERMOCUPLES

LOCAL CON RESISTENCIAS ELECTRICAS

(PWHT LOCAL MADE WITH ELECTRICAL RESISTANCES)
DISTRIBUCION CIRCUNFERENCIAL DE
LOS 4 TERMOPARES ,1 EN CADA EJE
4 TERMOPARES
(CIRCUMFERENTIAL DISTRIBUTION )

TIPO DE T.TERMICO CONDICIONES REQUERIDAS

TIPE OF H.T. RELEVADO DE REQUIRED CONDITIONS
ESFUERZOS
HORNO (STRESS RELIEF) LIBRE DEL AMBIENTE HASTA. 400ºC (752ºF) °C
(FURNACE) FREE TO AMBIENT

REGISTRO CICLO TERMICO INICIO A FIN ASCENSO VELOCIDAD / HR. MAXIMA 100°C (212ºF) °C / HR
REGISTER THERMAL CYCLE (BEGINNING TO END) HEATING SPEED MAX. BY HOUR

CICLO MANUAL VELOCIDAD PROMEDIO 100°C(212ºF) °C / HR

CYCLE- SPEED AVERAGE
+15°C (+59ºF )
PROBETA N/A SOSTENIMIENTO TEMPERATURA 615°C (1139ºF) °C -15°C (- 59ºF) °C
SAMPLE HOLDING TEMPERATURE
+15 ºC (+59ºF )
FIJACION DE LOS TERMOPARES TIEMPO 60 MINTUS. -0 (- 32ºF) HR
POSITION OF TERMOCUPLE'S TIME

DIRECTOS EN EL CUERPO VELOCIDAD / HR. MAX. 100°C(212ºF)

( DIRECT TO THE SHELL) SPEED MAX. BY HOUR

4 TERMOCOPLES MINIMO DESCENSO LIBRE AL AMBIENTE A PARTIR DE: 400ºC (752ºF)

4 (THERMOCUPLES MINIMUM) COOLING FREE AT THE AMBIENT FROM

TIPO: AIRE CALMADO (STILL AIR)

TYPE

ESPECIFICACION Y GRADO DEL MATERIAL BASE SA-516-70

SPECIFICATION AND GRADE OF BASE MATERIAL

ESPESOR EN LA JUNTA DE SOLDADURA 1.00" NOMINAL THICKNESS

THICKNESS IN THE WELD JOINT

CODIGO Y/O PROCEDIMIENTO APLICABLES DEL CLIENTE O AXIS INDUSTRIAL. ASME CODE SECTION I
APPLICABLE CODE AND / OR PROCEDURES OF THE CUSTOMER OR AXIS INDUSTRIAL

OBSERVACIONES: INCLUDED SOAK BAND

OBSERVATIONS

FECHA HECHO POR: REVISADO POR: AUTORIZADO POR:

DATE MADE BY REVISED BY AUTHORIZED BY

04-jun-19 FIRMA FIRMA FIRMA

SIGNED SIGNED SIGNED

F.GAC-20.1