bosgasclean 2014 b vessel

RISK BASED INSPECTION

BOS PLANT ‘B’ VESSEL

HOOD & GAS CLEANING

SYSTEM

RBI1

BOS 'B' VESSEL HOOD & GAS

CLEANING RBI DOCUMENT

Date 22 FEBRUARY 2015

Plant STEELMAKING

Item BOS PRIMARY ‘B’ VESSEL HOOD

& GAS CLEANING SYSTEM

Assessment

Team

FABRICATION ENGINEER; TONY SMITH

MECHANICAL ENGINEER; ROB BLAKE

PRODUCTION MANAGER; STUART DUNBAR /

ALEX SMITH

STRUCTURAL INSPECTOR; GLYN SHERWOOD

FABRICATION TEAM LEADER; COLIN WAITT

MATERIALS SPECIALIST; IAN RICHARDSON

2BOS 'B' VESSEL HOOD & GAS


ASSESSMENT GROUP AND TASK DETAIL


CLEANING RBI DOCUMENT3

INDEX PAGE

PAGE No

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39

SKETCH IDENTIFYING INSPECTION AREAS

SIGNATORIES OF REVIEW GROUP

TYPICAL DETAILED INSPECTION REQUIREMENT





MINIMUM THICKNESS DRAWING













TYPICAL FEEDBACK FROM FABRICATION GROUP






LIST OF COMPONENTS FOR RISK BASED ASSESSMENT

ASSESSMENT OF THE RISK

RESULT OF THE REVIEW PROCEDURE & CHANGE OF SCOPE / INSPECTION

STRUCTURAL INSPECTORS WORKLIST & SAP INFORMATION

TYPICAL STRUCTURAL INSPECTORS SAP TASK

TYPICAL NOTIFICATION TASK FOLLOWING INSPECTION

PAGE TITLE

TITLE PAGE

ASSESSMENT GROUP AND TASK DETAIL

INDEX PAGE

STEPS FOR QUALITATIVE RISK BASED INSPECTION

STEPS FOR QUALITATIVE RISK BASED INSPECTION (CONT)

BASIC INFORMATION

DAMAGE MECHANISM'S

STEPS FOR QUALITATIVE RISK BASED INSPECTION

STEP (1)

Identify the equipment, the structure or the system to be risk assessed. BOS PRIMARY ‘B’ VESSEL HOOD & GAS

CLEANING SYSTEM

STEP (2)

Define the system boundaries – Agree the boundary limits (i.e. isolation valves) then decide which systems, components, or

items etc, within the boundary, should be included within the scope of the RBI assessment. These will be those that have the

most influence on safety, production or environment should a failure occur, especially those that have history of failure.

THE LOWER HOOD, THE MOVEABLE HOOD, THE FIXED HOOD FROM ITS MOUTH TO THE 60M HEADERS. THE

QUENCHER WATER SEAL WITHIN THE 60M VENTURI, DOWN STREAM TO THE EXIT DUCT OF THE PRIMARY I.D.FAN

INCUDING ALL TANKS AND DRAIN PIPES WITHIN THIS DESCRIPTION.

STEP (3)

Assemble the RBI team – Five (minimum) competent persons with relevant experience or knowledge of the system/item, its

design, inspection history or maintenance history.

Five experts (one of which will act as facilitator) are typically;

Structural Engineer or Pipe Design Engineer (Design Standards knowledge)

Structural Inspector (Report on past/current conditions)

Maintenance Engineer (Past repair/failure history)

Production Manager/Owner (Costing future repair/renewal)

Damage mechanism Expert (Metallurgist/structural inspector to identify the relevant corrosion or other damage

mechanisms)

STEP (4)

Gather the information - List the relevant equipment or Plant items within the system, item or structure, incl breaking the

system down into circuits where appropriate (areas exposed to similar environments incl proximity to personnel).

Make a list of all the critical items, along with their characteristics including;

Modification/repair history

Previous inspection report findings

Original design/construction data

Maintenance records

Age

Likely damage mechanisms and consequence



STEP (5)

Evaluate all the critical items – Evaluate each item with regard to likelihood and consequence of failure within the existing

Inspection time frame. Consider all available information, such as the effectiveness of current maintenance regimes, existing

condition, design, past history/failures, modifications (incl temp repairs), inspection records, operating/process conditions, etc.

Note – any items identified at this stage as being unfit for purpose (integrity already compromised) will not be entered on to the

Matrix, until an action to repair/renew has been agreed by the Plant Engineer.

STEP (6)

Compile the Risk Matrix's – The team will need to agree the definitions in the consequence table, i.e what is acceptable.

(In some cases a leak might be acceptable, in others it will not, for instance a water leak as apposed to a toxic fluid leak)

Place each item on the Matrix (consequence x likelihood = RISK)

STEP (7)

Consider ways to reduce the RISK – Consider actions to reduce the likelihood or consequence of the highest risk items.

Note – the responsibility for carrying out agreed actions remains with the Plant Manager/Owner.

STEP (8)

Decide new inspection frequencies/scope –Prioritise the risks and decide new inspection periods and scope.

Consider creating separate inspections for items in Risk Cat 3 or 4. (shorter inspection periods)

The highest remaining risk item will determine the new inspection frequency.

After agreeing new inspection frequencies, repeat step 6 to quantify your result.



BASIC INFORMATION

DEPARTMENT STEELMAKING PRODUCT BOS GAS

PLANT BOS PRODUCT CLASS COMAH

LOCATION PRIMARY ‘B’

VESSEL HOOD AND

GAS CLEANING

DESIGN

PRESSURE

25 - 200mbarg

REPORT

NUMBERS

DESIGN

TEMPERATURE

1700deg C max

EXISTING

INSPECTION

VISUAL /

THICKNESSMINIMUM

THICKNESS

Variable, 4mm at

flooded disc

EXISTING

FREQUENCY

32 WEEKLY



DAMAGE MECHANISM’s / SYSTEM CONSTRUCTION

TYPICAL DAMAGE MECHANISM TYPICAL SYSTEM COMPONENTS

INTERNAL CORROSION / EROSION X SUPPORT STRUCTURE X

EXTERNAL CORROSION X PIPE SUPPORTS X

CREVICE CORROSION X PIPE MAIN

CORROSION UNDER INSULATION AUXILIARY PIPEWORK X

MECHANICAL IMPACT X DEAD LEGS

VIBRATION BELLOWS X

FLANGE JOINTS X

CLADDING

DRAIN POTS



LIST COMPONENTS AND CIRCUITS FOR RISK BASED ASSESSMENT



MATRIX

KEYCOMPONENT DAMAGE MECHANISM

MINIMAL

THICKNESS

ALLOWED

EXTERNAL CONDITIONESTIMATED

RETIREMENT DATEPRODUCT CHARACTERISTIC

PROXIMITY TO

PERSONNEL

DESIGN QUALITY /

FITNESS FOR

PURPOSE

EFFECTIVENESS OF

CURRENT

INSPECTION REGIME

AGE AND PAST FAILURE

INFOPOTENTIAL FAILURE MODE

1ID Fan inlet duct internal / external

corros ion

7mm Paint breakdown,

loca l i sed rusting

Not Planned Unpredicted external

corros ion

regularly 2/3

persons

Good Good None Air ingress , explos ion

2

ID Fan cas ing internal eros ion /

external corros ion

7mm Poor condition, regular

repairs required due

to loca l i sed rusting,

process eros ion

prior to end 2015 Unpredicted internal

eros ion / internal

corros ion

regularly 2/3

persons

Good Good Severa l years past,

system fa i l due to

explos ion, (a i r ingress )

Air ingress , explos ion

3ID Fan exi t duct internal / external

corros ion

5.8mm Paint breakdown,



corros ion

regularly 2/3

persons

Good Good None Release of CO

4ID Fan sump dra in legs internal / external

corros ion

3mm Stainless s teel Not Planned Non predicted regularly 2/3

persons


5Slag Gantry east

vertica l leg

internal / external

corros ion




corros ion

regularly 2/3

persons


6Slag gantry horizonta l

duct

internal / external

corros ion




corros ion

Occas ional ly Good Good None Air ingress , explos ion

7Slag Gantry west

vertica l leg

internal / external

corros ion




corros ion

regularly 2/3

persons


8

Radiation section

explos ion door

internal eros ion /

external corros ion

2.0mm (hood

tubes)

Poor condition, thinning

tubes, regular failures,

several Structural P1

notifications

New Hood planned

for 2017

insta l lation

Unpredicted internal

eros ion / internal

corros ion

Occas ional ly Good Good Severa l years past,



Release of CO, water

leakage

9

Quencher Venturi internal / external

corros ion


covering of process

debris

Plan to replace as

part of Hood

replacement 2017


eros ion / internal

corros ion

regularly 2/3

persons

Good Good None Release of CO, water

leakage

10

Primary Elbow internal / external

corros ion

7mm Poor condition, regular

repairs required due to

localised rusting, process

erosion

Considering replacing

as part of Secondary

Scrubbing upgrade


eros ion / internal

corros ion

regularly 2/3

persons


leakage

11

Quencher Seal tank &

dra in legs

internal / external

corros ion


covering of process

debris


corros ion

regularly 2/3

persons


leakage

12

Disc Scrubber internal / external

corros ion

4.3mm Poor condition, regular

repairs required due to

localised rusting, process

erosion

Considering replacing

as part of Secondary

Scrubbing upgrade


eros ion / internal

corros ion

regularly 2/3

persons


leakage

13

Secondary Elbow internal / external

corros ion


covering of process

debris


corros ion

regularly 2/3

persons


leakage

14

Quencher Feed tank &

dra in legs

internal / external

corros ion


covering of process

debris


corros ion

Occas ional ly Good Good None Release of CO, water

leakage

15

Mist El iminator internal / external

corros ion


covering of process

debris


corros ion


leakage

16

Ground Floor duct internal / external

corros ion, metal

splash


covering of process

debris


corros ion

regularly 2/3

persons




Air ingress , explos ion

17

Duct Seal tank & dra in

legs

internal / external

corros ion


covering of process

debris


corros ion

regularly 2/3

persons

Good Good None Air ingress , explos ion,

release of CO. Water

leakage

18

OG System manway

doors

internal / external

corros ion

relative to

system

location

Paint breakdown Not Planned Unpredicted external

corros ion

regularly 2/3

persons

Good Good Severa l years past, G F

Duct door fa i led. Other

doors no reported fa i l s

Air ingress , explos ion,

release of CO. Water

leakage

19

Lower Hood internal / external

corros ion

2.0mm (hood

tubes)

Paint breakdown,

covering of process

debris

Plan to replace as

part of Hood

replacement 2017


eros ion / internal

corros ion


leakage, flame

release

20

Moveable Hood internal / external

corros ion

2.0mm (hood

tubes)

Paint breakdown,

covering of process

debris

Plan to replace as

part of Hood

replacement 2017


eros ion / internal

corros ion


leakage, flame

release

21

Lower fixed hood internal / external

corros ion

2.0mm (hood

tubes)




notifications

Plan to replace as

part of Hood

replacement 2017


eros ion / internal

corros ion

regularly 2/3

persons


system overpressure

damaged Hood


leakage, flame

release

22

Upper Fixed hood internal / external

corros ion

2.0mm (hood

tubes)




notifications

Plan to replace as

part of Hood

replacement 2017


eros ion / internal

corros ion

regularly 2/3

persons


system overpressure

damaged Hood


leakage, flame

release

CATASTROPHIC 1 2 2 4 4

SUBSTANTIAL 1 2 2

16,18

3

19,20

4 2,8,21,22

MARGINAL 1 1 1 2

1,3,4,5,6,7,9,10,11,12, 13,14,15,17

2

NEGLIGABLE 0 1 1 1 1

UNFORSEABLE IMPROBABLE REMOTE POSSIBLE LIKELY

COMPONENTS AND CIRCUITS RISK ASSESSMENT MATRIX

UNACCEPTABLE RISK - 4Inspection / scope increased

MODERATE RISK - 3Scope of inspection increased

LOW RISK - 2Inspection and scope adequate

VERY LOW RISK - 1Inspection can be decreased

NO RISK - 0

Inspection not required

KEY

NEGLIGABLELittle or no structural damage or deterioration of protective coatings, no risk to safety or environment

MARGINALBreakdown in protective coatings, surface corrosion, light impact damage, minor injury

SUBSTANTIALSevere deflection, loss of member thickness > 25%, partial collapse / detachment leading to unsafe structure, major injury, production stoppage, minor loss of containment

CATASTROPHICTotal failure / buckling / collapse, major leakage, loss of containment, fatal injury, environmental damage, loss of production

LIKELY TO BE EXPECTED

POSSIBLE COULD OCCUR

REMOTE UNLIKELY

IMPROBABLE VERY UNLIKELY

UNFORSEABLE CLOSE TO ZERO

RISK / PROBABILITY DESCRIPTION



ASSESSMENT OF THE RISK

ITEM DAMAGE MECHANISM RISK (DESCRIPTION) RISK LEVELACTIONS TO REDUCE

RISKNEW RISK RATING

16,18Internal / external corrosion

Thinning of parent metal (air ingress)

2Consider renewing of paint protection 2

1,3,4,5,6,7,9,10,11, 12,13,14,15,17

Internal / external corrosion

Thinning of parent metal (air ingress)

2 Consider renewing of paint protection

2

19,20Internal erosion / external corrosion

Thinning of tubes (water / HM mix) 3

Inspection frequency to be increased 3

2,8,21,22

Internal erosion / external corrosion

Thinning of tubes (water / HM mix)Thinning of parent metal (air ingress)

4Inspection frequency to be increased

4

ACTIONS TO BE TAKEN TO REDUCE THE LIKELYHOOD OF FAILURE

ITEMCURRENT INSPECTION

FREQUENCYTYPE / SCOPE

OVERALL RISK CATEGORY

REVISED INSPECTION FREQUENCY

REVISED SCOPE

16,18Reline major stop / 32

weeklyVisual and U/T

thickness readings2

No ChangeNone

1,3,4,5,6,7,9,10,11, 12,13,14,15,17

Reline major stop / 32 weekly

Visual and U/T thickness readings

2No Change

None

19,20Reline major stop / 32

weeklyVisual and U/T

thickness readings3 Additional inspections on

1500 Lives Maint outage

Additional Thermovisionprior to Reline outage

2,8,21,22

Reline major stop / 32 weekly

Visual and U/T thickness readings

4

Additional inspections on 1500 Lives Maint

outage

Additional Thermovision prior to

Reline outage

NEW INSPECTION FREQUENCY AND SCOPE



RESULT OF THIS REVIEW PROCEDURE

INSPECTION / SCOPE CHANGE AS A RESULT OF THE REVIEW

B VESSEL Maint plan + Func Location

WASTE GAS ID FAN (VENTILATOR)

ID Fan Inlet Ducting 216841 1000-080-1968-0024-0027

ID Fan Casing 216851 1000-080-1968-0024-0027

ID Fan Exit Ducting 216851 1000-080-1968-0024-0027

ID Fan Sump Drain Legs 212649 1000-080-1968-0024-0037

PRIMARY WASTE GAS SYSTEM

Slag Gantry East Vertical Leg 215627 1000-080-1968-0024-0009

Slag Gantry Hortizontal Duct 215261 1000-080-1968-0024-0009

Slag Gantry West Vertical Leg 212533 1000-080-1968-0024-0009

Radiation Section Explosion Door 213217 1000-080-1968-0024-0002

Quencher Venturi 215926 1000-080-1968-0024-0005

Primary Elbow 217164 1000-080-1968-0024-0006

Quencher Seal Tank & Drain Legs 214850 1000-080-1968-0024-0008

Disc Scrubber 216832 1000-080-1968-0024-0012

Secondary Elbow 217562 1000-080-1968-0024-0007

Quencher Feed Tank & Drain Legs 213679 1000-080-1968-0024-0022

Mist Eliminator 213608 1000-080-1968-0024-0014

Ground Floor Duct 212834 1000-080-1968-0024-0009

Duct Seal Tank & Drain Legs 214930 1000-080-1968-0024-0043

OG System Inspection Doors 229753 1000-080-1968-0001-0011

HOOD INSPECTIONS

Lower Hood 213171 000-080-1968-0024-0001

Moveable Hood 213656 1000-080-1968-0024-0004

Lower Fixed Hood 213181 1000-080-1968-0024-0001

Upper Fixed Hood 216706 1000-080-1968-0024-0001

Vessel reline - structural inspection

checklist



STRUCTURAL INSPECTORS WORKLIST & SAP INFORMATION



TYPICAL STRUCTURAL INSPECTORS SAP INSPECTION TASK



TYPICAL NOTIFICATION (WORK RAISED) TASK FOLLOWING INSPECTION



TYPICAL FEEDBACK FROM FABRICATION MAINTENANCE GROUP

ID Fan Inlet Ducting Procedure

INSPECTION LIST

Carry out a visual inspection of casing,system

supports, access platform,visualy inspect vane

cylinder linkage & supports,vane box,fabric bellows.

1.Inspect casing-Carry out assessment of the

protective coating,detailing the

condition(blistering/flaking).Do a random UT

thickness test of the full casing at max spacings of

500mm,including any areas suspect of suffering

internal corrosion/any areas rea

2. Access ladder and platforms. Check the

condition and security of ladder rungs stringers and

safety hoops including securing brackets / bolts.

Detail all impact damage, corrosion, condition of

anchorage points / brackets, check handrail for

security and

3.System suports- Identify any missing or loose

bolts at connections including any weld defects such

as cracks,marking up for repair.

4.Vane cylinder-Visualy inspect the vane cylinder

linkage and supports.

5.Fabric bellows-Check for signs of

deteroration,wear and leakage.

KC4200 V0 Job Catalogue Enquiry-Basic Details 27/09/07 15:08

Resp TSM Cost Centre 1968 BOS WASTE GAS CLEANING

Plant Reg 22 PRIMARY WASTE GAS CLEANING - A VESSEL

Plant Item 27 3700HP I/D FAN & FLARE STACK RCM Ind

Job ------Key Name----- Class -------------Job Title------------------ P/Req

075 STRUCT INSPECTION 02 RELINE INSPECTION OF FAN INLET DUCTING 1

------------Job Description------------- Grade No Time Dept Dur Cards

CARRY OUT VISUAL INSPECTION OF CASING TO 1994 01

ENSURE INTEGRITY OF SYSTEM, CARRY OUT Priority

RANDOM THICKNESS CHECKS TO FULL SECTION, Critical C

CARRY OUT VISUAL INSPECTION OF SYSTEM Cost Allocation

SUPPORTS, VISUALLY INSPECT VANE CYLINDER

LINKAGE & SUPPORTS. VISUAL INSPECTION OF SI 2 4.00 OrderNo

ACCESS PLATFORM & LADDERS. Drawings

Orig ----Prior Job----- Gen Proc -----Safety Procedures----- Gp.Id S/R Recal

23D ZYX ZPA 1

---------------Frequency Details---------------- ---Major Stop Details----

Code Freq --Start(Base) 1--- --Start(Base) 2--- Code Freq Sh Day Wk Start

Cycle Sh Day Week Yr Sh Day Week Yr

W 32 4 1 16 0 0 00 0 A 01 4 7 02 01



ID Fan Casing Procedure

INSPECTION PROCEDURE

Carry visual inspection of I.D fan casing, holding down

structures access walkway and staircase.

1. ID Fan casing-carry out a visual inspection of all the ID

Fan casing plates and identify any areas suffering from

corrosion or internal wear. Check also for signs of buckling

or distortion possibly caused by thinning of the casing

plates,(problem areas are around the shaft on the drive side

and around the casing on the fan path) carry out a visual

inspection of the welds and report all weld fractures.

2.Carry out a systematic UT thickness test of the fan casing

at a max spacing of 500mm including any areas suspect of

suffering from internal erosion, any areas found showing

readings of <3mm should be subject to a UT scan (letter

box) of 100mm x 100mm. All readings below 3mm should

be reported to the relevent supervisor, who will organise

immediate repair.

Visual inspection

3.Holding down structures-inspect the fan stuctures

concrete foundation and identify any spalling or cracked

concrete.Check all holding down bolts are secure and

report any corrosion.

4.Access walkway and staircase-Inspect all stair treads

for wear/deformed including security bolts for corrosion.

Check all handrailing for corrosion and security, check the

condition of the protective coating. Inspect all open mesh

gratings including the grating support structure.





076 STRUCT INSPECTION 02 RELINE INSPECTION OF I.D. FAN CASING 1



ENSURE SYSTEM SECURITY, CARRY OUT RANDOM Priority

THICKNESS CHECKS OF CASING AREA, VISUAL Critical C

INSPECTION OF HOLDING DOWN STRUCTURES, Cost Allocation

VISUAL INSPECTION OF ACCESS WALKWAY &

STAIRCASE. SI 2 6.00 OrderNo

Drawings


23D ZYX ZPA 1




W 32 4 2 15 0 0 00 0 A 01 4 7 02 01



ID Fan Exit Ducting Procedure

Carry out a visual inspection of:

Swan neck, Stainless steel expansion Bellows, Silencer, T piece,

Transition duct and Fabric bellows to ensure integrity of ducting.

1. Swan neck, check for paint deterioration / corrosion, check

welds on channel stiffeners / between ducting and stiffeners for

crevice corrosion. Carry out visual inspection of swan neck to Stack

flanged connection looking for signs of leakage. Check bolts for

severe corrosion and identify any found missing or loose. Carry out

thickness checks to ducting at a max spacing of 500mm, including

any areas suspected of suffering internal errosion or severe external

corrosion (i.e above channel stiffeners where plant process debris

collects, signs of buckling or distortion). Any areas showing

readings < 3mm should be subject to a scan (Min 100mm x

100mmm) to dermine the area requiring repair. Mark all areas

requiring repair and report to relevant plant supervisor who will

organise immediate repair.

2. Stainless expansion Bellows Check convolutes for signs of

fatigue/cracking. Any suspect areas should be subject to DPI.

Check and report any signs of impact damage and misalignment.

3. Silencer Thickness check ducting at a max spacing of 500mm /

check for paint deterioation signs of corrosion. Check welds for

defects

4. T piece and transition ducting Check for paint deterioration /

corrosion to casings,Check bolts in flanges for severe corrosion and

identify any missing or loose. Check around welded connection of "T"

piece for leakage thinning of shell casing .Carry out thickness checks

to ducting at a max spacing of 400mm including any areas suspected

of suffering internal errosion or severe external corrosion i.e. signs of

buckling, distortion, pin holes . Any areas showing readings <3mm

should be subject to a scan (min 100mm x 100mm) to dermine the

area requiring repair, mark all areas requiring repair and report to

relevant plant supervisor who will organise immediate repair.Check

bolted connections in north and south sides supporting columns.

5.Fabric bellows Check bellows for signs of deterioration, tears, holes, .

any signs of leakage





077 STRUCT INSPECTION 02 RELINE INSPECTION OF FAN EXIT DUCTING 1



ENSURE SYSTEM SECURITY, CARRY OUT RANDOM Priority

THICKNESS CHECKS TO FULL SECTION, REPORT Critical C

ON FABRIC BELLOWS CONDITION, VISUAL Cost Allocation

INSPECTION OF SILENCER SECTION, VISUAL

INSPECTION OF SWAN NECK ENTERING INTO SI 2 4.00 OrderNo

CHIMNEY. Drawings


23D ZYX ZPA 1




W 32 4 2 15 0 0 00 0 A 01 4 7 02 01



ID Fan Sump Drain Legs Procedure

INSPECTION LIST

Carry out inspection of I.D. Fan Sump Drain Legs to ensure

integrity and length of.

Visual inspect

Drain Legs Check for paint deterioration and corrosion. Check

all flanges for signs of leakage, loose, missing or severly

corroded bolts. Carry out thickness checks to full length of

carbon pipe (Original thickness recorded at 7.6mm). Carry out

visual inspection of stainless steel (sump end) leg length to

ensure that they are below sump water level and form a seal.

1 Sump drain legs

Sump Handrail Check handrail for defects I.e. missing or loose

bolts impact damage to rails, paint deterioration, corrosion.

Check access gate

2 Ensure pipe work is of correct length

UT thickness tests

1 Ut thickness testing of pipe work



Plant Item 37 3700HP I/D FAN - SUMP PUMP RCM Ind


010 STRUCT INSPECTION 02 RELINE INSPECTION OF SUMP DRAIN LEGS 1


CARRY OUT VISUAL INSPECTION OF SUMP 1994 01

DRAIN LEGS TO ENSURE INTEGRITY OF SYSTEM Priority

ENSURE PIPEWORK IS OF CORRECT LENGTH, Critical C

CARRY OUT THICKNESS CHECKS OF PIPEWORK. SI 2 3.00 Cost Allocation

OrderNo

Drawings


23D ZYX ZBP 1




W 32 4 2 21 0 0 00 0 A 01 4 7 02 01



Slag Gantry East Vertical Leg Procedure

INSPECTION LIST

Carry out inspection of casing, 20metre level pivot point

frames and pin connections to casing, crane drivers access

walkway level slide bearing frame

Visual inspect

1.Inspect casing-Carry out assessment of the protective

coating,detailing the condition(blistering/flaking).Do a

random UT thickness test of the full casing at max spacings

of 500mm,including any areas suspect of suffering internal

erosion / any areas reading <3mm should be subject to a

scan (min 100mmx100mm) to determine the area to repair.

1 Inspect casings

2. Pivot point frame. Check around pin to esure welded

connection to ducting is intact and pin is horizontal. Check

frame for defects I.e. distortion, welds cracking and if frame

is vertical on supporting steelwork.

2 System supports at 20m level

3. Slide bearing and frame. Check channel bracings for

integrity I.e. bolted connections any signs of distortion. Check

wear plates on shell casing and channel bracings to ensure

integrity off.

3 Slide bearing frame

4 Pivot point frame

UT thickness tests

1 Random Ut Thickness tesing of full section



Plant Item 09 DAHL TUBE RCM Ind


025 STRUCT INSPECTION 02 RELINE INSPECTION OF EAST VERTICAL LEG 1





VISUALLY INSPECT SYSTEM SUPPORTS @ 20M Cost Allocation

LEVEL, VISUAL INSPECTION OF SLIDE

BEARING FRAME, VISUAL INSPECTION OF SI 2 12.00 OrderNo

PIVOT POINT FRAME. Drawings


23D ZYX ZPA 1




W 32 4 2 15 0 0 00 0 A 01 4 7 02 01



Slag Gantry Hortizontal Duct Procedure

INSPECTION LIST

Carry out inspection of Slag Gantry horizontal duct,

platforms G and platform F.

Slag Gantry Horizontal duct. Carry out a visual

inspection of Ducting looking for signs of leakage, paint

deterioration or corrosion. Check door flanges for crevice

corrosion. Carry out Visual inspection of internal

handrailing. Carry out thickness checks to ducting at a max

spacing of 1metre, including any areas suspected of

suffering internal erosion or severe external corrosion. Any

areas showing readings< 3mm should be subject to a scan

(min 100mm x 100mm) to determine the area requiring

repair. Mark all areas requiring repair and report to relevant

plant supervisor who will organise immediate repair.

Visual inspect

Platforms G and F. Check supporting steelwork and

welded connections to duct casing. Check Bolted

connections for crevice corrosion. Check open mesh

panels for defects and if secured with clips. Check

handrailing and ladder access. Check connecting walkway

for same.

1 Inspect casings

2 Access walkways and ladders

UT thickness tests





026 STRUCT INSPECTION 02 RELINE INSPECTION OF SLAG GANTRY DUCT 1





VISUAL INSPECTION OF ACCESS WALKWAYS AND Cost Allocation

LADDERS. SI 2 12.00

OrderNo

Drawings


23D ZYX ZPA 1




W 64 4 2 47 0 0 00 0 A 02 4 7 02 02



Slag Gantry West Vertical Leg Procedure

INSPECTION LIST

carry out a visual inspection of casing,system supports

and vertical access ladder.

1.Inspect casing-Carry out assessment of the

protective coating,detailing the

condition(blistering/flaking).Do a random UT thickness

test of the full casing at max spacings of

500mm,including any areas suspect of suffering internal

corrosion/any areas reading <3mm should be subject to

a scan (min 100mmx100mm) to determine the area to

repair.

2.System suports- Identify any missing or loose bolts at

connections including any weld defects such as

cracks,marking up for repair.

3.Vertical access ladder-Check the condition and

security of the ladder rungs,stringers and safety hoops

including securing brackets/bolts.Detail all impact

damage,corrosion,contition of protective

coating,condition of anchorage point.





027 STRUCT INSPECTION 02 RELINE INSPECTION OF WEST VERTICAL LEG 1





CARRY OUT VISUAL INSPECTION OF SYSTEM Cost Allocation

SUPPORTS, VISUAL INSPECTION OF VERTICAL

LADDER ACCESS. SI 2 4.00 OrderNo

Drawings


23D ZYX ZPA 1




W 64 4 2 47 0 0 00 0 A 02 4 7 02 02



Radiation Section Explosion Door Procedure

INSPECTION LIST

Carry out inspection of Explosion door and pivot structure.

Water seal trough and associated access platforms.

Visual inspect

Explosion door and pivot structure. Carry out visual

inspection of door checking for severe corrosion and condition

of door seal plate. Check pivot assembly for defects

1 Explosion door

Water seal trough. Visual inspection of trough looking for

severe corrosion wall height of trough and over flow pipe work

2 Explosion door pivot structure ans supports

Access platforms. Check Bolted connections for crevice

corrosion. Check open mesh panels for defects and if secured

with clips. Check handrailing and ladder access. Check Internal

walkway and ladders for same.

3 Water seal trough

4 access platforms and ladder

Chimney. Check for defects I.e. Holes, impact damage.

Check condition of refactory.

5 chimney



Plant Item 02 FURNACE HOOD - EXPLOSION DOOR RCM Ind


032 STRUCT INSPECTION 02 RELINE INSPECTION OF EXPLOSION DOOR 1


CARRY OUT VISUAL INSPECTION OF 1994 01

EXPLOSION DOOR AND ITS PIVOT STRUCTURE Priority

AND SUPPORTS, INTEGRITY OF WATER SEAL Critical C

TROUGH. VISUAL INSPECTION OF ACCESS Cost Allocation

PLATFORMS & LADDER, VISUAL INSPECTION

OF CHIMNEY. SI 2 6.00 OrderNo

Drawings


23D ZYX ZPA 1




W 32 4 2 15 0 0 00 0 A 01 4 7 02 01



Quencher Venturi Procedure

INSPECTION LIST

Carry out visual inspection of outer casing, internal

inspection of wear plates water seal trough and dipper

arrangement.

Outer casing. Check for paint deterioration / corrosion to

casings,Check bolts in flanges of vane assembly

(underslung platform) for severe corrosion and identify any

missing or loose. Carry out thickness checks to ducting at

a max spacing of 400mm including any areas suspected of

suffering internal errosion or severe external corrosion

i.e.leakage, signs of buckling, distortion (north wall around

spray water inlet pipes). Any areas showing readings

<3mm should be subject to a scan (min 100mm x 100mm)

to dermine the area requiring repair, mark all areas

requiring repair and report to relevant plant supervisor who

will organise immediate repair.

Visual inspect

Wear plates. Carry out internal inspection of wear plates

looking for distortion caused through heat damage . Check

wear plates for cracking in securing welds. Visual

inspection of wear plate face checking for erosion.

1 Outer casing

2 Water seal trough

Water seal trough and Dipper arrangement. Visual

inspection of trough and dipper arrangement checking that

dipper plate sits lower than water level in trough and

forming gas tight seal. Check for heat distortion to internal

trough walls.

3 Dipper arrangement

UT thickness tests

1 UT thickness test walls

Measure

Venturi vanes and report



Plant Item 05 VENTURI HOPPER/QUENCHER TROUGHS RCM Ind


031 STRUCT INSPECTION 02 RELINE INSPECTION OF QUENCHER VENTURI 1


CARRY OUT VISUAL INSPECTION OF OUTER 1994 01

CASING TO ENSURE INTEGRITY OF SYSTEM, Priority

CARRY OUT VARIOUS THICKNESS READINGS Critical C

OF WALLS, REPORT ON CONDITION OF WATER Cost Allocation

SEAL TROUGH AND ASSOCIATED DIPPER

ARRANGEMENT, MEASURE VENTURI VANES AND SI 2 8.00 OrderNo

REPORT. Drawings


23D ZYX ZPA 1




W 32 4 2 15 0 0 00 0 A 01 4 7 02 01



Primary Elbow Procedure

INSPECTION LIST

Carry out inspection to The outer casing,system

supports, access ladders, platforms andExpansion

bellows

1. Outer casing, Check for paint deterioration /

corrosion. Check welds on channel stiffeners / between

ducting and stiffeners for crevice corrosion. Carry out

visual inspection of elbow casing looking forsigns of

leakage. Check bolts for severe corrosion and

identifyany found missing or loose. Carry out thickness

checks to the ducting at a max imum spacing of 500mm,

including any suspected of suffering from internal

erosion, areas showing signs buckling or distortion.Any

areas showing readings< 3mm should be subject to a

scan (min 100mm x 100mm) to determine the area

requiring repair.

Visual inspect

2.System supports Identify any missing or loose bolts

at connections, including any defects such as cracks,

marking up any for repair

1 Outer casing

3. Access ladder and platforms. Check the condition

and security of ladder rungs stringers and safety hoops

including securing brackets / bolts. Detail all impact

damage, corrosion, condition of anchorage points /

brackets, check handrail for security and damage,

check Kennedy grating for security i.e. clips

4. Expansion Bellows. Check the convolutes for signs

of fatigue / cracking. Any suspect areas should be

subject to D,P,I. Check and report any signs of impact

damage and misalignment.



Plant Item 06 PRIMARY ELBOW RCM Ind


023 STRUCT INSPECTION 02 RELINE INSPECTION OF PRIMARY ELBOW 1


CARRY OUT VISUAL INSPECTION OF OUTER 01


REPORT ON STRUCTURAL SUPPORTS FOR SYSTEM Critical C

VISUAL INSPECTION OF ACCESS LADDER & Cost Allocation

PLATFORMS, REPORT ON CONDITION OF

EXPANSION BELLOWS. SI 2 8.00 1994 OrderNo

Drawings


23D ZYX ZPA 1




W 64 4 2 07 1 0 00 0 A 02 4 7 02 02



Quencher Seal Tank & Drain Legs Procedure

Carry out inspection of Quencher seal tank and drain

leg checking for paint deterioration, corrosion, wear

and any signs of leakage

INSPECTION LIST

1. Tank body. Carry out visual inspection of Quencher

seal tank main body. Check all flanges and cover

plates for signs of crevice corrosion. Check all welds

for cracking / defects. Check internal Tri-may base

plates for deterioration / and securing welds. Carry out

thickness checks to tank body at a max spacing of

400mm including any areas suspected of suffering

internal errosion or severe external corrosion. Check

bolted flanges for loose or missing bolts."Mark up"

and report any areas requiring repair to relevant plant

supervisor for immediate repair.

Visual inspect

1 Tank body

2. Drain leg. Scaffold access required for this part of

the inspection. Carry out visual inspection of down leg

looking for paint deterioration, corrosion and any signs

of leakage.Take thickness readings at regular

intervals on down pipe subject to access. A line scan

should be taken accross the (extrados) top bend to

determine any errosion and areas requiring repair.

Carry out internal inspection to ensure down leg

length is below exit trough level and a gas seal will be

formed.

2 Supply pipe work

3 Export pipe work

3. Exit pipe work. Carry out visual inspection of pipe

and flanged connection looking for paint deterioration,

corrosion and any sign of leakage. Check bolts for

severe corrosion, loose or any missing. Carry out

thickness checks to bottom of bend and sides of pipe

also below inspection hatch to determine any erosion.

"Mark up" and report any areas requiring repair to

relevant plant supervisor for immediate repair.

UT thickness tests

1 UT thickness tests of tank body



Plant Item 08 QUENCHER SEAL TANK RCM Ind


028 STRUCT INSPECTION 02 RELINE INSPECTION OF TANK & DRAIN LEGS 1


CARRY OUT VISUAL INSPECTION OF TANK BODY SI 2 8.00 1994 8.00 01

AND SUPPLY & EXIT PIPEWORK TO ENSURE Priority

SYSTEM INTEGRITY, CARRY OUT THICKNESS Critical C

CHECKS TO TANK BODY. Cost Allocation

OrderNo

Drawings


90M ZYX ZBP 1




W 32 4 2 15 0 0 00 0 A 01 4 7 02 01



Disc Scrubber Procedure

INSPECTION LIST

Carry out inspection of shell casing from primary elbow to

secondary elbow,ducting supports, expansion bellows,access

platforms and ladders.

Ducting. Check for paint deterioration / corrosion to

casing,Check bolts in flanges for severe corrosion and identify

any missing or loose. Carry out thickness checks to ducting at

a max spacing of 500mm including any areas suspected of

suffering internal errosion or severe external corrosion i.e.

signs of buckling, distortion. Any areas showing readings

<3mm should be subject to a scan (min 100mm x 100mm) to

dermine the area requiring repair, mark all areas requiring

repair and report to relevant plant supervisor who will organise

immediate repair.

Visual inspect

Ducting supports. Visual inspection of supports identifying

any missing or loose bolts at connections including any weld

defects such as cracks,marking up and inform relevant

supervisor.

1 Outer casing

Expansion bellows. Check convolutes for signs of

fatigue/cracking. Any suspect areas should be subject to DPI.

Check and report any signs of impact damage and

misalignment.

Access ladder and platforms. Check the condition and

security of ladder rungs stringers and safety hoops including

securing brackets / bolts. Detail all impact damage, corrosion,

condition of anchorage points / brackets, check handrail for

security and damage, check Kennedy grating for security i.e.

clips



Plant Item 12 DISC SCRUBBER RCM Ind


041 STRUCT INSPECTION 02 RELINE INSPECTION OF DISC SCRUBBER 1




REPORT ON SYSTEM SUPPORTS @ 50M LEVEL AN Critical C

40M LEVEL, REPORT ON CONDITION OF Cost Allocation

EXPANSION BELLOWS, VISUAL INSPECTION OF

ACCESS PLATFORMS AND LADDERS. SI 2 8.00 OrderNo

Drawings


23D ZYX ZPA 1




W 32 4 2 15 0 0 00 0 A 01 4 7 02 01



Secondary Elbow Procedure

INSPECTION LIST

Carry inspection of secondary elbow shell casing and

drain leg

Visual inspect

Secondary Elbow. Carry out visual inspection to

internal and external shell casing to identify any defects

i.e. Impact damage, crevice corrosion on door flanges

condition of internal seperator plate. Carry out thickness

checks to shell casing at max 500 spacing. Including

any areas suspected of suffering internal errosion or

severe external corrosion. Any areas showing readings

<3mm should be subject to a scan (100mmx100mm) to

determine the area requiring repair. Mark all areas

requiring repair and report to relevant plant supervisor

who willorganise immediate repair.

1 Outer casing

Drain leg.Carry out visual inspection of down leg

looking for paint deterioration, corrosion and any signs

of leakage.Take thickness readings at regular intervals

on down pipe subject to access. A line scan should be

taken accross the (extrados) top bend to determine any

errosion and areas requiring repair. Mark all areas

requiring repair and report to relevant plant supervisor

who will organise immediate repair.

2 External walkways

UT thickness tests

1 Random UT thickness tests of casing



Plant Item 07 SECONDARY ELBOW RCM Ind


012 STRUCT INSPECTION 02 RELINE INSPECTION OF SECONDARY ELBOW 1


CARRY OUT VISUAL INSPECTION OF OUTER 01

CASING TO ENSURE INTEGRITY OF SYSTEM, 1994 Priority

CARRY OUT RANDOM THICKNESS CHECKS OF Critical C

CASING, VISUAL INSPECTION OF EXTERNAL Cost Allocation

WALKWAYS. SI 2 8.00

OrderNo

Drawings


23D ZYX ZPA 1




W 32 4 2 15 0 0 00 0 A 01 4 7 02 01



Quencher Feed Tank & Drain Legs Procedure

INSPECTION LIST

Carry out inspection to Tank body, inlet and out let

pipework, weir wall and man hole door access.

Visual inspect

Tank body. Carry out a visual inspection of Tank

looking for signs of leakage, paint deterioration or

corrosion. Check door flanges for crevice corrosion.

Carry out Visual inspection of internal ladder. Carry out

thickness checks to tank walls roof and floor at a max

spacing of 1metre, including any areas suspected of

suffering internal erosion or severe external corrosion.

Any areas showing readings< 3mm should be subject

to a scan (min 100mm x 100mm) to determine the area

requiring repair. Mark all areas requiring repair and

report to relevant plant supervisor who will organise

immediate repair.

1 Tank body

Weir wall. Check integrity of wall, height of wall is

higher than east side internal drain legs to form seal.

Carry out random thickness checks to weir wall.

2 Supply pipe work

Inlet and outlet pipework (drain legs).Carry out

visual inspection of all pipework looking for signs of

leakage, paint deterioration and corrosion. Check all

flanged connections checking for loose severly

corroded or missing bolts. Carry out thickness checks

to all pipe work at random areas and areas liable to

suffer from internal errosion (extrados).



Plant Item 22 QUENCHER FEED TANK RCM Ind




CARRY OUT VISUAL INSPECTION OF TANK BODY 01

AND SUPPLY & EXIT PIPEWORK TO ENSURE Priority

SYSTEM INTEGRITY, CARRY OUT RANDOM Critical C

THICKNESS CHECKS TO TANK BODY AND PIPE - Cost Allocation

WORK, ENSURE WEIR WALL IS FIT FOR PURPOS

AND CARRY OUT RANDOM THICKNESS CHECKS. SI 2 12.00 OrderNo

Drawings


23D ZYX ZBP 1




W 32 4 2 29 0 0 00 0 A 01 4 7 02 01



Mist Eliminator Procedure

INSPECTION LIST

Carry out inspection of Mist eliminator shell casing, drain leg

access walkways, ladders and system supports.

1. Shell casing, Check for paint deterioration / corrosion.

Check welds on channel stiffeners / between ducting and

stiffeners for crevice corrosion. Carry out visual inspection of

casing looking for signs of leakage. Check bolts for severe

corrosion and identify any found missing or loose. Carry out

thickness checks to the ducting at a maximum spacing of

500mm, including any suspected of suffering from internal

erosion, areas showing signs buckling or distortion.Any

areas showing readings< 3mm should be subject to a scan


repair.

Visual inspect

Drain leg. Carry out visual inspection of down leg looking for

paint deterioration, corrosion and any signs of leakage.Take

thickness readings at regular intervals on down pipe subject

to access. A line scan should be taken accross the

(extrados) top bend to determine any errosion and areas

requiring repair.

1 Outer casing

4.Access walkway and ladders-Inspect all ladder rungs

for wear/deformed including security bolts for corrosion.

Check all handrailing for corrosion and security, check the

condition of the protective coating. Inspect all open mesh

gratings including the grating support structure.

2 Access walk ways and ladders

3.System suports- Identify any missing or loose bolts at

connections including any weld defects such as

cracks,marking up for repair.



UT thickness tests



Plant Item 14 MIST ELIMINATOR RCM Ind


011 STRUCT INSPECTION 02 RELINE INSPECTION OF MIST ELIMINATOR 1




CARRY OUT RANDOM THICKNESS CHECKS OF Critical C

CASING, VISUAL INSPECTION OF ACCESS Cost Allocation

WALKWAYS AND LADDERS, VISUAL INSPECTION

OF SYSTEM SUPPORTS @ 20M/30M LEVEL SI 2 8.00 OrderNo

Drawings


23D ZYX ZPA 1




W 32 4 2 15 0 0 00 0 A 01 4 7 02 01



Ground Floor Duct Procedure

INSPECTION LIST

Ducting. Check for paint deterioration / corrosion. Check

ducting for signs of leakage. Check all welds for defects /

cracking. Check man hole door for crevice corrosion to

door and shell casing flanges. Carry out thickness testing

to ducting at maximum spacing of 1metre, including any

areas suspected of suffering internal erosion or showing

severe external corrosion. Any areas showing < 3mm

should be subject to a scan (min 100mm x 100mm) to

determine the area requiring repair / replacement.

Mark all areas requiring repair and report to relevant plant

supervisor.

Twin Expansion bellows. Check convolutes for signs of

fatigue / cracking. Any suspect areas should be subject to

DPI. Check and report any signs of impact damage and

misalignment.

Visual inspect

Support tension bars. Carry out visual inspection of

tension bars checking welded connections to ducting and

supporting steelwork. Check pins for any signs of

movement.

1 Casing

Drain Legs. Check for any signs of leakage. Check

welded connection to shell casing for defects / cracking.

Check bolts in flanged pipe connections. Thickness

check pipework on all bends and in random areas to

pipework.

2 Support tension bars

Access ladders and platform. Check the condition and

security of ladder rungs stringers and safety hoops

including securing brackets / bolts. Detail all impact


brackets, check handrail for security and damage, check

Kennedy grating for security i.e. clips

3 Access platforms and ladders

4 Twin expansion bellows

UT thickness tests

1 Random UT thickness tests of full ducting


Plant Reg 24 PRIMARY WASTE GAS CLEANING - B VESSEL



021 STRUCT INSPECTION 04 RELINE INSPECTION OF GROUND FLOOR DUCT 1



ENSURE INTEGRITY OF SYSTEM, VISUAL Priority

INSPECTION OF SUPPORT TENSION BARS, Critical C

CARRY OUT RANDOM THICKNESS CHECKS TO Cost Allocation

FULL SECTION OF DUCT, VISUAL INSPECTION

OF ACCESS PLATFORMS AND LADDERS, VISUAL SI 2 8.00 OrderNo

INSPECTION OF TWIN EXPANSION BELLOWS. Drawings


23D ZYX ZPA 1




W 32 4 2 32 0 0 00 0 B 01 4 7 02 01



Duct Seal Tank & Drain Legs Procedure

INSPECTION LIST Carry out inspection of Duct seal tank and drain legs

Visual inspect

Duct seal tank. Carry out a visual inspection of tank

body looking for signs of leakage, paint deterioration or

corrosion. Check around all pipe work connections into

tank for defects I.e. Weld defects / cracks / corrosion.

Check door flange for crevice corrosion.Carry out Visual

inspection of weir wall checking that height of wall is

greater than drain leg length. Carry out thickness checks

to tank body and internal weir wall at a max spacing of

500mm, including any areas suspected of suffering

internal erosion or severe external corrosion. Any areas

showing readings< 3mm should be subject to a scan


repair. Mark all areas requiring repair and report to

relevant plant supervisor who will organise immediate

repair.

1 Tank body

2 Drain legs

Drain legs Carry out visual inspection of all pipework

looking for signs of leakage, paint deterioration and

corrosion. Check all flanged connections checking for

loose severly corroded or missing bolts. Carry out

thickness checks to all pipe work at random areas and

areas liable to suffer from internal errosion (extrados).

3 Access platforms and ladders

4 Twin expansion bellows

Bund wall. Check bund wall for integrity, height·

· The bund walls have to be strong enough to contain the

contents of the tank without danger of collapse.

· The bund walls have to be high enough to avoid jetting

failure – i.e. jets of liquid out over the bund wall.

· The bund has to be impervious to water

UT thickness tests

1 Random UT thickness tests of Tank

2 Random UT thickness tests of Pipe work

3 Carry out thickness tests of Weir wall



Plant Item 43 DUCT SEAL TANK RCM Ind




CARRY OUT VISUAL INSPECTION OF TANK BODY 01

AND DRAIN LEGS TO ENSURE SYSTEM Priority

INTEGRITY, CARRY OUT RANDOM THICKNESS Critical C

CHECKS TO TANG AND PIPEWORK. ENSURE WEIR Cost Allocation

WALL IS FIT FOR PURPOSE, CARRY OUT

RANDOM THICKNESS CHECKS. SI 2 12.00 1994 OrderNo

Drawings


23D ZYX ZBP 1




W 32 4 2 15 0 0 00 0 A 01 4 7 02 01



OG System Inspection Doors Procedure

INSPECTION LIST Carry out inspection of O.G. system doors

CARRY OUT INSPECTION OF ALL SYSTEM DOORS

AS PER LIST

System Doors. Carry out visual inspection of open doors as per

list, looking for crevice corrosion to flange / door faces. Any

flanges with a loss of 50% to be replaced relevant plant

supervisor informed. Inspect door hinges for wear, Check welded

connection of hinges to ducting and door.

ENSURE ALL DOORS MEET THE REQUIRED

STANDARDS AS

DETAILED ON RELEVANT DRAWINGS

DOOR LIST

1) 70M EXPLOSION DOOR

2) 60M EAST RADIATION DOOR

3) 60M WEST RADIATION DOOR

4) 60M VENTURI HOPPER DOOR

5) 60M EAST VENTURI THROAT DOOR

6) 60M WEST VENTURI THROAT DOOR

7) 45M HOOD DOOR

8) 50M PRIMARY ELBOW TOP DOOR

9) 50M PRIMARY ELBOW BOTTOM DOOR

10) 50M FLOODED DISC DOOR

11) 40M SECONDARY ELBOW SQUARE DOOR

12) 40M SECONDARY ELBOW ROUND DOOR

13) 35M MIST ELIMINATOR SOUTH DOOR Example of crevice corrosion

14) 35M MIST ELIMINATOR NORTH DOOR

15) 30M VERTICAL DUCT ROUND DOOR

16) GROUND FLOOR DAHL TUBE DOOR

17) SLAG GANTRY HIGH LEVEL EAST DOOR

18) SLAG GANTRY HIGH LEVEL WEST DOOR

19) I.D. FAN INLET DUCT DOOR

20) I.D. FAN IMPELLER COMPARTMENT DOOR


Plant Reg 01 CIVIL ENG WORKS - BUILDINGS,DRAINAGE,ETC

Plant Item 11 STRUCTURE RCM Ind


032 STRUCT INSPECTION 02 RELINE INSP 'A' VESSEL SYSTEM DOORS 1


CARRY OUT INSPECTION OF ALL SYSTEM DOORS 1994 01

AS PER ELEMENTS LIST, ENSURE ALL DOORS Priority

MEET THE STANDARDS REQUIRED ON RELEVANT Critical C

DRAWINGS. SI 2 8.00 Cost Allocation

OrderNo

Drawings


23D ZYX ZBP 1




W 32 4 2 15 0 0 00 0 A 01 4 7 02 01



Lower Hood Procedure

INSPECTION LISTCARRY OUT INSPECTION OF HOOD TUBES AND

MEMBRANES,VISUAL INSPECTION OF RING MAIN.

Tubes and membrane. Visual inspection of tubes

looking for leakage, cracking, pitting and condition of

membrane. Carry out thickness testing to tubes

covering 10% (1 in every 10) of hood. Any tubes

<3mm thickness test tubes adjacent to it.

Visual inspect

Water Ring main.Visual inspection of pipe looking

for leakage, cracking, pitting and condition of pipe

connections.

1 Lower hood tubes amd membranes

2 Ring main and feed pipes

UT thickness tests

1 UT Thickness test tubes. Coverage 10%. Length 1m from lower bend up over and

with probe as close as posible to the membranes.



Plant Item 01 FURNACE HOOD RCM Ind


138 STRUCT INSPECTION 02 RELINE INSPECTION OF LOWER HOOD 1


CARRY OUT VISUAL INSPECTION OF HOOD SI 2 4.00 1994 01

TUBES AND MEMBRANES, REPORT THICKNESS Priority

READINGS OF VARIATION OF TUBES ALONG Critical C

LENGTH, VISUAL INSPECTION OF RING Cost Allocation

MAINS AND FEED PIPES.

OrderNo

Drawings


23D ZYX ZPA 1




W 32 4 2 15 0 0 00 0 A 01 4 7 02 01



Moveable Hood Procedure

INSPECTION LIST

Carry out inspection of moveable hood Tubes and

membranes, water ring mains, walkways and support

structure.

Tubes and membrane. Visual inspection of tubes looking

for leakage, cracking, pitting and condition of membrane.

Carry out thickness testing to tubes with probe as close as

posible to the membranes covering 10% (1 in every 10) of

hood. Any tubes < 3mm thickness test tubes adjacent to it.

Visual inspect

Water Ring main.Visual inspection of pipe looking for

leakage, cracking, pitting and condition of pipe outlet

connections.

1 Movable hood tubes amd membranes

Access ladders and platforms. Check the condition and

security of ladder rungs stringers and safety hoops including

securing brackets / bolts. Check and detail all impact


brackets, check handrail for security and damage, check

Kennedy grating for security i.e. clips


Support structure. Check all beams joists and angle bars

that form supporting structure for impact damage. Check

bolted connections for loose or missing bolts3 Walk ways and support structure

UT thickness tests

1 UT Thickness test tubes. Coverage 10%. Length 1m from lower bend up over

and with probe as close as posible to the membranes.

TEM's



Plant Item 04 MOVEABLE HOOD RCM Ind


060 STRUCT INSPECTION 02 RELINE INSPECTION OF MOVEABLE HOOD 1


CARRY OUT VISUAL INSPECTION OF HOOD 1994 01

TUBES AND MEMBRANES, REPORT ON THICKNESS Priority

READINGS OF VARIATION OF TUBES ALONG Critical C

LENGTH, VISUAL INSPECTION OF RING MAINS Cost Allocation

AND FEEDER PIPES, VISUAL INSPECTION OF

WALKWAYS & SUPPORT STRUCTURE. SI 2 8.00 OrderNo

Drawings


23D ZYX ZPA 1




W 32 4 4 15 0 0 00 0 A 01 4 7 02 01



Lower Fixed Hood Procedure

INSPECTION LIST

Carry out inspection of Hood tubes and membranes,Hood

support rollers on 40metre level, hood supports on

50metre level.

Tubes and membrane. Visual inspection of tubes

looking for leakage, cracking, pitting and condition of

membrane. Carry out thickness testing to tubes with probe

as close as posible to the membranes covering 10% (1 in

every 10) of hood. Any tubes <3mm thickness test tubes

adjacent to it. Report all defects and low reading area to

plant supervisor

Visual inspect

Hood support rollers. Check alignment of supporting

steelwork and roller. Check around welded connection to

hood for cracking

1 Lower fixed hood tubes amd membranes


3 Walk ways and support structure

4 Support rollers on 40m level

5 Hood support on 50m level

6 N2/02 Mains pipe work

50metre Hood supports.Check condition of welded

connections to hood any signs of cracking should be

further investigated with a N.D.T. method. check packing

under hood supports to ensure hood is supported.

UT thickness tests

1 UT Thickness test tubes at 35m level. Coverage 10%. Length 1m from lower

bend up over and with probe as close as posible to the membranes.

2 UT Thickness test tubes below 50m expansion joint and at the intermediate

positions. Coverage 10%. Length 1m from lower bend up over and with probe

as close as posible to the membranes.





139 STRUCT INSPECTION 02 RELINE INSPECTION OF LOWER FIXED HOOD 1


CARRY OUT VISUAL INSPCTION OF HOOD TUBES 1994 01

AND MEMBRANES, REPORT ON THICKNESS Priority

READINGS OF TUBES @ 35M LEVEL AND ALSO Critical C

BELOW 50M EXPANSION JOINT AND AT INTER- SI 2 6.00 Cost Allocation

MEDIATE POSITIONS, REPORT ON HOOD

SUPPORT ROLLER @ 40M LEVEL. REPORT ON OrderNo

HOOD SUPPORT @50M LEVEL.INC N2/02 MAINS Drawings


23D ZYX ZPA 1




W 32 4 2 15 0 0 00 0 A 01 4 7 02 01



Upper Fixed Hood Procedure

INSPECTION LIST

Carry out inspection of upper Fixed Hood, Hood

supports and 70m tension rods 50 Metre level link pipes

Fixed hood. Visual inspection of tubes looking for

leakage, cracking, pitting and condition of membrane.

Carry out thickness testing to tubes covering 10% (1 in

every 10) of hood. Any tubes <3mm thickness test tubes

next to it

Visual inspect

Hood supports. Check condition of welded

connections to hood any signs of cracking should be

further investigated with a N.D.T. method. check packing

under hood supports to ensure hood is supported.

1 Upper fixed hood tubes amd membranes

Tension Rods. Check springs on 70metre level for

fatigue, stress fractures. Check 60metre level east and

west side welded connections to hood for cracking.

Check pin and alignment of rod

2 Hood support at 60m level

Link pipes. Check 50metre level Link pipes and

header pipe for any signs of leakage. Carry out

thickness tests to random areas of each Link pipe and

header pipe.

3 70m tension rods

UT thickness tests

1 UT Thickness test tubes at 50m level. Coverage 10%. Length 1m from lower


2 UT Thickness test link pipes at 50m level.

3 UT Thickness test tubes at 60m venturi. Coverage 10%. Length 1m from lower






140 STRUCT INSPECTION 02 RELINE INSPECTION OF UPPER FIXED HOOD 1


CARRY OUT VISUAL INSPECTION OF HOOD TUBE 01

AND MEMBRANES, REPORT ON THICKNESS Priority

READINGS OF TUBES @ 50M LEVEL AND ALSO Critical C

60M VENTURI, THICKNESS READINGS OF 50M Cost Allocation

LINK PIPES, REPORT ON HOOD SUPPORT @

60M LEVEL AND 70M TENSION RODS. SI 2 12.00 1994 OrderNo

Drawings


23D ZYX ZPA 1




W 32 4 2 15 0 0 00 0 A 01 4 7 02 01



MINIMUM THICKNESS DRAWING





SKETCH IDENTIFYING INSPECTION AREAS



SIGNATORIES OF WORKING GROUP AGREEING WITH RBI REVIEW

bosgasclean 2014 b vessel

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