PROJECT WB029M – 1 x 120 TPH AFBC BOILER

CUSTOMER BIRLA CELLULOSE, KHARACH, GUJARAT

FOR INTERNAL REFERENCE ONLY

REPORT ON SITE VISIT – 14 – 17 JULY 2009

This visit is continuation to the visit made by EAPL team of Shri SK, SRK & SELF on 09 June2009. Please refer MOM dated 09 June 2009 circulated by mail on 12 June 2009.

As per the MOM refered above, material and manpower arranged and schedule was sent toCustomer to carry out the activities decided during Boiler shutdown. Self and Mr S Rameskumarvisited site to access the situation and inspect the APH.

DAY 1 – 14 JULY 2009

Insulation of APH was removed with the help of BC’s maintenance contractor in the rear, leftside and air inlet to APH. Visual inspection carried out thoroughly. During this inspectioncraters and cracks observed in the following areas;a. bottom plate of inlet transition ductb. partition plate between FD & PA duct at inlet transition ductc. left side casing plated. lower end of top bank casing cum air passage (outlet )at rear side of APH

Also noticed, that the partition plate inside the FD inlet transition duct to APH was notprovided. This plate is to distribute the flow evenly towards APH. At the rear side, verticalchannel stiffeners were not provided exactly where the casing plates has given away. Thoughthe partition and stiffener plates are not provided as per drawing, the localized crack andcraters are sounds like the raw material is brittle. It was observed during the visual inspectionthat tubes, expansion of tubes and tube sheets are in good condition.

The casing plate at rear of APH was cut and opened for a height of 1.05 mtr and width of 2.50mtr.

DAY 2 – 15 JULY 2009

- The FD inlet transition duct to APH was cut open to access & attend the cracks.- Partition plate between FD & PA ducts at APH inlet was cut opened for 0.5 mtr width and

height of 4.0 mtr.- The bottom plate of inlet transition duct was cut opened for the width of the duct.- New plates were prepared at ground to close all the above-mentioned opening.- At rear side the opening was closed with new plate and welding completed inside and

outside.- The furnace inside was inspected for the healthiness of bed coils, air nozzles, thermo

couples and furnace wall refractory and found perfect.- The new bed ash cooler conveyor layout was discussed with Customer. The changes

requested by customer would be checked and replied.

DAY 3 – 16 JULY 2009

- New partition plate at APH inlet lifted and fitup completed.

- Piping from deaerator outlet to BFP to HP heater in the old system and new systeminstalled by BC was studied for knowledge sake.

- The full second half of the day was disturbed by heavy rain, but welding inside duct wascontinued.

- Test pieces of various locations of failure area has been collected for testing.

Self & Mr Rameshkumar left site on 16 July 2009 around 18.00 hrs.

Note: Please see the photos in H:/ PROJECTS / WB029M / PHOTOS / BOILER SHUTDOWN JULY09 – APH PROBLEMS

Decision to be taken on the following;

1. Whether the APH can be closed after attending the leakage or to be checked completely. Ifit has to be checked completely, then our insulation team has to be arranged to removeand reinstall insulation of entire APH casing.

2. EAPL agreed to supply the modified bed ash conveyor and erecting the same. BC is askingEAPL to modify the ash handling piping according to the new bed ash conveyor.

3. BC asking to remove all the bracings provided for the conveyor leg supports, for easy accessunder the airbox.

4. BC asks EAPL to do the overhauling of Drag chain conveyor.