Section VI Technical Specifications Part 3 Technical Specification for U4 Rehabilitation Work

TABLE OF CONTENTS 3.1 REHABILITATION REQUIRMENTS 3.2 EQUIPMENTS TO BE REHABILITATED 3.3 WORK TO BE DONE BY OTHER CONTRACTOR 3.4 WORK AND SERVICES TO BE INCLUDED 3.5 INSPECTION AND TEST 3.6 WELDING ROD SUPPLIED BY CONTRACTOR
3.7 ATTACHMENTS 3.7.1 ATTACHMENT 1: SCOPE OF REPLACMENT 3.7.2 ATTACHMENT 2: SCOPE OF WORKS

3. Technical Specification for U4 Boiler

Rehabilitation Work
This part specifies "scope of works" for Rehabilitation of the steamgenerating unit and its associated equipment for AL-MUSSAIB Thermal Power Station unit 4 boiler.

3.1 REHABILITATION REQUIRMENTS 3.1.1 Original Boiler Specification

Type: Single Drum Radiant, Single Reheat, Natural Circulation Manufacturer: Babcock Hitachi K.K Evaporation: 980 t / h at MCR Steam Conditions: Superheater Outlet: 171.6 bar (g), 541 C Reheater Outlet: 41.9 bar (g), 541 C Economizer Inlet Temp.: 251.7 C Draft System: Forced Draft Fuel: Natural gas, Heavy Fuel Oil, Crude oil Commercial Operation: March 1989 Reference Drawings: Title: General Arrangement of Boiler (Side View) Drawing No.: KUO-160-497 Title: General Arrangement of Boiler (Front View) Drawing No.: KUO-160-498 Title: General Arrangement of Boiler (Plan View) Drawing No.: KUO-160-499
S.O.E REPUBLIC OF IRAQ Al-MUSSAIB POWER STATION UNIT NO. 1,2,3&4 Radiant EL-PASO Type May .1987. Aug 1987 Contract no. 412-0425

Fig.1 SCOPE OF REPLACEMENT FOR AL-MUSSAIB NO.4

Max continuous rating Superheater outlet pressure Final steam temperature Reheat steam temperature Feed water temperature Fuel

980 t/h (2,160,900 lb/ln) 175 kg/sq.cm (2.489 lb/sq.in) 541 C (1.005F) 541 C (1.005F) 257C (459F) Oil & Gas

3.1.2 General Requirements for Rehabilitation Works of Unit 4 Boiler

1) General This general requirement covers design, inspection, rehabilitation work, test after assembling works related to Unit 4 boiler. 2) General Requirements (1) The technical Specification is supplemental to the Special Condition and shall constitute a part of the contract (2) The Contractor shall select materials of boiler pressure parts with the same materials as the original ones and all pressure parts to be replaced shall be of seamless tubes, in any case. If the Contractor wants to change other material than the original one, explanation documents including material comparison table and the reason to change the material shall be submitted to the Engineer for approval. (3) The Contractor shall apply the latest ASME Boiler and Pressure Vessel Code for design, material, nondestructive examination, welding and other relevant items for the boiler rehabilitation work. (4) The Contractor shall submit the following rehabilitation procedure, inspection procedure and test procedure and carry out the rehabilitation work, inspection and test according to the relevant procedure: 1) Boiler rehabilitation procedure including arrangement of heavy material handling equipment, temporary stage arrangement, large size opening for bring in and out of materials, basic schedule of removing the existing major components and installing major new components, inspection formats for boiler pressure parts and auxiliary equipments. 2) Welding procedure including welding method, welding bevels, pre-heating, post weld treatment, nondestructive examination and judgment procedure for boiler pressure parts. 3) Welders qualification test procedure for pressure part welding, 4) Furnace leak test, 5) Boiler Chemical Cleaning(including boiler blowing S/H and R/H)) 6) Boiler hydrostatic test procedure, 7) Boiler drying test (5) Hazardous Areas and Electrical Equipment The Contractor shall suitably design electrical installation in the hazardous area, especially burner areas.

3.2 EQUIPMENTS TO BE REHABILITATED

The Contractor shall replace the existing deteriorated facilities or parts with new ones and repair the existing deteriorated facilities and parts .The rehabilitation scope shall include the following main parts: 1- Replace Water wall panels and baffle wall panels. 1) Boiler front , side , rear and hopper water wall panels with refractory , casing and supports , insulation and lagging , accessories 2) Baffle wall panels with refractory, casing and supports, insulation and lagging, accessories 3) Primary S/H support tubes 2- Retractable Soot Blowers for Boiler 3- Superheater and Reheater Attemperators with Spray Nozzles 4- Gas and air ducts & expansion joints for gas & air ducts (Fabrication works is included) 5- Boiler Insulation Materials and Boiler Outer Gladding including Gas and Air ducts 6- Boiler Casings 7- Arrangement and setting of the existing Main Oil Burners, Pilot Burners ,Oil and Gas Lighter ,Burner Pulse Igniter and Burner Air Register

3.2.1 Water Wall Panels up to FL+ 25,000 including lower headers

1) General Since the existing water wall panels from the boiler bottom to the level height approximately 25,000 mm are badly deteriorated, the Contractor shall erect all water wall panels such as front, rear, right and left side water wall panels, front and rear hopper panels, baffle wall panels and primary S/H support tubes, roof tubes baffle support tubes, including inlet and outlet headers. 2) Scope of Work 2.1 The Contractor shall erect all front and rear water wall panels, right and left side wall panels, front and rear hopper panels, baffle wall panels and primary superheater support tubes, baffle support tubes, roof tube, including water inlet and outlet headers with connection stubs, 16 burner opening portions, inspection holes with sealing aspirating air connection and 2 openings with seal and aspirating air connection. 2.2 The Contractor shall fix buck-stays, corner links, tie bars, tie bar lugs, tie bar pins and temporally support of wind box and other miscellaneous materials required for assembly works .
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2.3 The Contractor shall erect new panels at the furnace heights as shown below: 1) Side Wall: FL+25,000 and partially 26,500 2) Front and Rear Wall: approximately FL + 25,000 3) Baffle wall support tubes: approximately FL+25,000 4) Primary S/H support tubes: Refer to the reference drawings. 2.4 The Contractor shall submit replacement procedure for new panels and support tubes to the Engineer for approval. 2.5 The contractor shall inspect & clean the down comer manifold & supply pipes which will be re-used after the inspection. 3) Procedure The Contractor shall submit the procedure in accordance with 3B11-1 General Requirement for Rehabilitation Works of Boiler. 4) Test and Inspection The following test and inspection shall be carried out witnessed by the supervisors of the Engineer and the Customer. a. Welding bevel inspection before welding b. Check of radiography examination test result for all butt welded portions, c. Hydrostatic test on boiler pressure parts, 5) Original Design Data of Furnace Type: B & W Membrane Wall Furnace Dimensions Approximately , Furnace Height (Lower Side) : 25,000 to 26,250 mm Furnace Height at Roof panels: Approximately FL+41,500mm Width: 10,972.8 mm Depth: 13,716 mm Design Pressure: 194.37 bar (g) Design Temp.: 416 C Tube Materials: - Material: JIS STBA 20 (equi. to SA 213T2) O.D. 63.5 mm, Thick. 7.6 & 6.4 mm - Material: JIS STBA 42 (equi. To SA 210A1) O.D. 63.5 mm, Thick. 6.4 mm - Material: JIS STBA 42 (equi. To SA 210A1) O.D. 75.4 mm, Thick. 7.6 mm Tube Pitch: 76.2 mm Out Diameter : 57mm for Baffle wall Support tubes 6) Reference Drawing Refer to Attached Drawing Title: Arrangement of Furnace Lower Side Wall Tubes
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Dwg No.: KUO-165-881 Title: Arrangement of Furnace Lower Front Wall Tubes Dwg No.: KUO-165-883 Title: Arrangement of Furnace Lower Rear Wall Tube Dwg No.: KUO-165-885 Title: Arrangement of Furnace Lower Front Wall Tubes Dwg No.: KUO-165-938 Title: Arrangement of Furnace Lower Rear Wall Tubes Dwg No.: KUO-165-940 Title: Arrangement of Furnace Upper Side Wall Tubes Dwg No.: KUO-165-880

3.2.2 Retractable Soot Blowers

1) General There are total 12 soot blowers for Unit 4 steam generator. The Contractor shall erect & replace all old soot blower sets. 2) Scope of Work 2.1The Contractor shall erect all soot blower sets (total 12 sets) including steam valves, air valves, electric motors, rack, pinion and other gear sets, lance tubes, soot blower covers, seal boxes, flexible hoses, bolts and nuts, gaskets and packing and lubricants including grease and other components for the soot blower sets. 2.2 The Contractor shall repair the existing soot blower support members including cleaning and painting if the existing support members are not appropriate for installing new soot blower set and dirty. 2. 3 The Contractor shall demonstrate smooth operation of the entire soot blower system and confirm that every seal is in good services while boiler in service. 3) Procedure The Contractor shall submit replacement procedures and soot blower operation test procedure to the Engineer for approval. 4) Test and Inspection The following test and inspection shall be carried out witnessed by the supervisors of the Engineer and the Customer. a. Visual inspection after cleaning and assembly of all soot blower sets, b. Operation test of the entire soot blower system, c. Confirmation no leakage from seal points, 5) Original Data Type: RSB-IIA (Long retractable type)

Automatic sequential steam blowing, electric motor driven, electrically operated type Manufacturer: Babcock Hitachi K. K. Number: 12 sets for one boiler Operating steam pressure: 41 kg/ cm2 g Rated Terminal Voltage: 380 V, # Phase, 50 Hz for induction motor Electric Motor Type: Totally enclosed type 6) Reference Drawing Title: Installation Drawing (RSB-IIA) Dwg No.: 981479-02

3.2.3 Superheater and Reheater Attemperators with Spray Nozzles

1) General There are two sets of superheater attemperators on superheated steam pipelines from primary superheater to secondary superheater and one attemperator on cold reheat pipeline to Reheater. Since the existing attemperators for controlling main steam temperature and hot reheat steam temperature are not enough as their functions, the Contractor shall erect & replace two complete sets of superheater attemperators with spray nozzles and one complete set of Reheater attemperator with spray nozzle 2) Scope of Work 2.1 the Contractor shall dismantle two complete sets of superheater attemperators with spray nozzles and one complete set of reheater attemperator with spray nozzle and remove them to an area that approved by the Customer. . 2.2 The Contractor shall erect two complete sets of superheater attemperators with spray nozzles and one complete set of reheater attemperator with spray nozzle. 2.3 Before cut-off of the existing attemperator, the Contractor shall fix the existing pipeline so as not to occur sagging or gap at welding bevel between the pipe and the objective attemperator. 2.4 The Contractor shall submit specifications and drawings of SH and RH attemperators and replacement procedure for the attemperators to the Engineer for approval. 3) Procedure The Contractor shall submit replacement procedure for the attemperators to the Engineer for approval. 4) Test and Inspection The following test and inspection shall be carried out witnessed by
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the supervisors of the Engineer and the Customer. . a. Preparation of cut-off of the existing attemperators and welding bevel inspection before welding. b. Radiography examination test results for butt-welded portions. 5) Original Data Refer to the Reference Drawings. 6) Reference Drawing Title: Arrangement of Superheater Attemperator Dwg No.: KU1-308-955 Title: Combined Documents of Spare Parts List and Fig. 1 SH Spray Nozzle Dwg No.: KU4-890-393 (Spare Parts List)

3.2.4 Gas and Air Ducts and Expansion Joints for Gas and Air Ducts
1) General the Contractor shall fixed and erect all air & gas ducts and all air & gas duct expansion joints that need to cut and erect expansion joints for gas ducts at ( ECO. OUTLET-1, ECO. OUTLET-2 , AH GAS INLET , GRF INLET-1 , GRF INLET-2 GRF INLET-3 AND GRF OUTLET METTALIC AND NON- METTALIC EXPANSION JOINTS) . For air ducts, the Contractor shall fixed all wind boxes and all wind box expansion joints and repair the damaged portions so as to use the existing air ducts and air duct expansion joints. 2) Scope of Work 2.1 the contractor shall dismantle insulation and gladding by safe way and remove its to the scrap area inside power station . 2.2 the contractor shall dismantle & cut the exist expansion joints ( ECO. OUTLET-1, ECO. OUTLET-2 , AH GAS INLET , GRF INLET-1 , GRF INLET-2 GRF INLET-3 AND GRF OUTLET METTALIC AND NONMETTALIC EXPANSION JOINTS) and remove its to the scrap area inside power station 2.3 the Contractor shall fix and erect all air & gas ducts and all air & gas duct expansion joints that need to cut and erect expansion joints for gas ducts at ( ECO. OUTLET-1, ECO. OUTLET-2 , AH GAS INLET , GRF INLET-1 , GRF INLET-2 GRF INLET-3 AND GRF OUTLET METTALIC AND NON- METTALIC EXPANSION JOINTS) . 2.4 the Contractor shall fix with temporary structure all wind boxes and all wind box expansion joints and repair the damaged portions so as to use the existing air ducts and air duct expansion joints. 2.5 The Contractor shall use the original dimensions and materials of the existing gas ducts and expansion joints for new gas ducts and
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expansion joints. If dimensions and materials of new gas duct and expansion joint are not same as the original ones, the Contractor shall indicate the difference and the reason clearly on the approval drawings of the gas ducts and expansion joints. 2.6 The Contractor shall use the original dimensions and materials of the existing wind boxes and expansion joints for new ones. If dimensions and materials of new wind boxes and expansion joints are not same as the original ones, the Contractor shall indicate the difference and the reason clearly on the approval drawings of the wind boxes and the expansion joints. 2.7 Before insulation works on gas and air ducts, the Contractor shall carry out air leak test for gas and air ducts to confirm no leakage at all bolted joints and welded joints at site. 2.8 the contractor shall erect new insulation and gladding for all air and gas ducts and expansion joints that was dismantle as above . 2.9 The Contractor shall inspect duct supports and repair if necessary. 3) Procedure The Contractor shall submit air leak test procedure for air and gas ducts. 4) Test and Inspection The following test and inspection shall be carried out witnessed by the supervisors of the Engineer and the Customer. a. Visual inspection after completion of installation work for gas ducts and wind boxes and cleaning and repair for air ducts. b. Air leak tests for air and gas ducts. 5) Original Data Original detail drawings for gas duct, wind boxes and gas duct expansion joints and wind box expansion joints are available at AlMussaib Thermal Power Station. 6) Reference Drawing Title: General Arrangement of Boiler (Side view) Sub-title: Location of Expansion Joint (1/3) Dwg No.: KUO-160-497 Title: General Arrangement of Boiler (Front view) Sub-title: Location of Expansion Joint (2/3) Dwg No.: KUO-160-498 Title: General Arrangement of Boiler (Plan view) Sub-title: Location of Expansion Joint (3/3) Dwg No.: KUO-160-499

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3.2.5 Boiler Insulation Materials and Boiler Outer Gladding

1) General the Contractor shall erect one complete set of boiler insulation materials and boiler outer gladding. 2) Scope of Work 2.1 the contractor shall dismantle all insulation and gladding up to level (26 m) by safe way to avoid effect to workers and employers health so the contractor shall provide container and bags to put the old insulation material in it. 2.2 The Contractor shall erect one complete set of boiler insulation materials and boiler outer gladding approximately up to level (26 m) . 2.3 Furnace insulation and gladding work shall be commenced after completion of furnace wall leak test and boiler hydrostatic pressure test. 2.4 The contractor shall erect the boiler insulation and gladding at the same specification ,quality and thickness as those of the original ones. The insulation shall be of at least two layers of insulation materials and wire mesh. 2.4 The Contractor shall submit specification of boiler insulation materials and replacement procedure for the insulation outer cladding to the Engineer for approval. 3) Procedure The Contractor shall submit replacement procedure for the boiler insulation and outer gladding materials to the Engineer for approval. 4) Test and Inspection The following test and inspection shall be carried out witnessed by the supervisors of the Engineer and the Customer.. a. Inspection after installation of the insulation materials and outer gladding. 5) Original Data Boiler Approximate Dimensions Height x Depth x Width: 26m x 13.7 m x 10.9 m Membrane Wall Temperature: Approximately 360 C Insulation Materials: MG felt with thickness of 50 mm Gladding material ALLUMINUIM 6). Reference Drawing As available in al-Mussaib thermal power station.

3.2.6 Boiler Casings

1) General
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Since the existing boiler casings are badly deteriorated, the Contractor shall erect boiler casings for boiler lower headers and furnace bottom hopper and replace the existing casings with new ones. The Contractor shall repair the rusty or corroded surfaces of the existing casing support members including painting for rust prevention. 2) Scope of Work 2.1 the contractor shall dismantle for the boiler casings such as casing for boiler lower headers and furnace bottom hopper and miscellaneous materials required and remove its to the scrap area inside power plant . The Contractor shall erect boiler casings such as casing for boiler lower headers and furnace bottom hopper and miscellaneous materials required for installing new casings and replace the existing casings with new ones. 2.2 The Contractor shall repair the rusty or corroded surfaces of the existing casing support members including touch-up painting after cleaning. 2.4 The Contractor shall submit specification and drawings of boiler casings and replacement procedure for the casings to the Engineer for approval. 2.5 The contractor shall inspect the boiler sling bolts at the furnace roof and their seal covers. Repair them if necessary. 3) Procedure The Contractor shall submit replacement procedure for the boiler casings to the Engineer for approval. 4) Test and Inspection The following test and inspection shall be carried out witnessed by the supervisors of the Engineer and the Customer.. a. Internal cleaning of boiler casings and inspection after repair of the existing casing support members. b. Inspection after installation of new casings. 5) Original Data Non. 6) Reference Drawing Refer to Attached Drawing. Title: General Arrangement of Boiler (Side View) Drawing No.: KUO-160-497 3.2.7 Main Oil Burners , Pilot Burners , Oil and Gas Lighter, Burner Pulse Igniter and burner air register 1) General
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There are total sixteen (16) oil burner gun atomizers and also total sixteen (16) pilot burners and total (16) oil and gas lighter and burner pulse igniter and (16) burner air register. Since the existing (Main Oil Burners ,Pilot Burners, Oil and Gas Lighter , Burner Pulse Igniter and burner air register) will not be replaced. The contractor shall fix , arrange and setting after water wall installation . 2) Scope of Work 2.1 There are total sixteen (16) oil burner gun atomizers and also total sixteen (16) pilot burners and total (16) oil and gas lighter and burner pulse igniter Since the existing (Main Oil Burners ,Pilot Burners, Oil and Gas Lighter , Burner Pulse Igniter and burner air register ) will not be replaced .The contractor shall fix ,arrange and setting after water wall installation . 2.2 The contractor shall be responsible of the work of the above equipments and operation performance as original specification after installation 3) Procedure The Contractor shall submit replacement procedure of (Main Oil Burners ,Pilot Burners, Oil and Gas Lighter , Burner Pulse Igniter and burner air register) to the Engineer for approval. 4) Test and Inspection The following test and inspection shall be carried out witnessed by the supervisors of the Engineer and the Customer.. a. Confirmation of assembly of existing (Main Oil Burners ,Pilot Burners, Oil and Gas Lighter , Burner Pulse Igniter and burner air register) 5) Original Data None. 6) Reference Drawing Title: Assembly of Y-Jet Atomizer Dwg No.: KU1-309-458

3.3 WORK TO BE DONE BY OTHER CONTRACTOR

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Except for the Contractor's scope of work described in section 3.2 EQUIPMENTS TO BE REHABILITATED, Rehabilitation and/or Overhaul work will be done by MoE or other contractor .

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3.4 WORK AND SERVICES TO BE INCLUDED

1) The contractor shall carry out the dismantling work for all parts and component related to the scope of rehabilitation as specified in section 3.2 EQUIPMENTS TO BE REHABILITATED 2) The Contractor shall provide all tools , consumable construction materials , construction equipments , component construction erection supervisors , manual labor for receiving , unloading , handling , storing , installing ( including alignment and safety measures such as temporary lifting devise , temporary monorail , temporary division floor , scaffolding and fire protection ) , nondestructive examinations , hydrostatic testing , and air leak testing , as required to rehabilitate the steam generator , all necessary auxiliary and accessory equipment in place accordance with attachment 1-2 , Scope of Supply and Works . 3) The Work shall be performed according to the classification of work indicated hereto, and the work shall be performed and completed by the party marked " 0 " in this description (Attachment- 1-2). Only the principle part of each work is mentioned in this classification. However , all the work indicated in drawings , specifications , erection and installation procedures and appropriate code requirements etc. designated by the customer shall be performed and completed by the party designated with the mark "0" . 4) The Contractor shall supply the following works: 1- All necessary arrangement work for handling and unloading the materials during installation work period . 2- Contractor shall have all responsibility for site storage of the equipment and material during installation work period .

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3.5 INSPECTION AND TEST

The following inspection and test shall be included: 3.5.1 Radiographic Inspection 1) Boiler tube and integral Piping comprehended in Boiler Proper The radiographic inspection of the field welds of Boiler tube and integral Piping comprehended in Boiler Proper shall be conducted by the Contactor according to ASME Code Sect. I , quantities of the field welding joints to be inspected are indicated in part 5. 2) Boiler pressure parts The radiographic inspection of the field welds of Boiler pressure parts shall be conducted by the Contractor according to ASME code B31.1, quantities of the field welding joints to be inspected are indicated in part 5. 3) Other Piping The radiographic inspection of the field welds for other piping, which will remove temporary for rehabilitation work, shall be conducted by the Contractor according to ASME code B31.1, quantities of the field welding joints to be defined at site. 4) Others 1- the quantities of the field welds , which are indicated in part 5 may be changed within plus or minus five (5)% , even through quantity is changed over 5% , the cost shall not be adjusted (in the same price). The re-shot cost for the required welds shall be covered by the Contractor 2- the contractor shall provide all inspection equipment , tools and consumables for the radiographic inspection . 3- the contractor shall dispatch certified NDE inspector who shall perform inspection and evaluate the result of the radiographic examinations required be ASME code . He also shall submit the official NDE report to the customer. 3.5.2 Boiler Hydrostatic Test Scope of work to be done by the contractor ; - Hanger lock and restoration for Hot reheat piping and Cold reheat piping - Inspection and witness hydro test where replaced and/or welded - CRP isolator rehabilitate, install and restore - Setting and remove gag for Safety valves. - Remove hydro test plug mounted in Safety valves.
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Out of scope of work by the contractor - Install and remove the hydro jig on MSV and RSV - Flushing boiler circuit before hydro test. - Feeding, Pressurizing boiler Superheater and Reheater circuit using existing equipment. - CRP isolator material supply. 3.5.3 Acid Cleaning In order to clean the interior of the steam generator and its piping , the acid cleaning design , supply and operations are to be performed : The contractor shall install and restore the terminal point of temporary acid cleaning piping connect to the boiler , the equipment and weld system of chemical cleaning will supplied by the contractor. 3.5.4 Pneumatic Pressurizing Test of Fuel Piping Fuel piping which temporary removed shall be leak tested by means of the Pneumatic Pressurizing ( compressed air and N2 gas) test method . The pressure shall be inspected by soap water, all necessary temporary equipment and materials including N2 gas shall be prepared by Contractor. 3.5.5 Leak Test of Boiler Seal, Aspirating Air Piping The boiler seal, aspirating air piping which temporary removed shall be inspected by means of the Pneumatic Pressurizing Test method with compressed air. All necessary temporary equipment and material for the leak test shall be prepared by the Contractor. 3.5.6 Shower Test For Welding Portion of Boiler Inner Casing & Ducts The contractor shall carry out the shower test for welding portion of boiler inner casing & ducts where rehabilitated. 3.5.7 Header Internal Inspection Contractor shall carry out the internal header cleaning and inspection for Baffle inlet header and water wall inlet headers and supply tube connected with down comers manifolds.

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3.6 WELDING ROD SUPPLIED BY CONTRACTOR

The contractor shall prepare and supply welding rods for boiler pressure parts and the welding rods for boiler pressure parts are listed in part 5, Contractor's welder shall be well trained. Welding rods for welders training shall be prepared by the contactor.

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3.7 ATTACHMENTS:
3.7.1ATTACHMENT 1: SCOPE OF REPLACMENT

Fig.1 SCOPE OF REPLACEMENT FOR AL-MUSSAIB NO.4

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TABLE-1 SCOPE OF MAIN REPLACEMENT PARTS

NO 1 2 3 4

7 8

QUANTITY MATERIAL REMARKS WEIGHT Furnace Water Wall 40 panels 190 ton Erection & Panel(FL+25 m) replacement Baffle wall panel 12 panels 20.5 ton Erection & Primary super heater 36 sets 25 kg x 36 replacement support tube Retractable Soot 6 packs 26.400 kg Erection & Blowers replacement Superheater and 3 pieces Erection & Reheater replacement Attemperators with Spray Nozzles expansion joints for 8 pieces For erection gas & air ducts . Gas & air ducts fixed gas and air ducts and adjust Boiler Insulation Complete Materials And Insulation Boiler Outer Gladding Boiler Casings Erection fixed & adjust Main Oil Burners Arrangement and Pilot Burners & and setting Oil and Gas Lighter and Burner Pulse Igniter and burner air register

ITEM

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Attachment 1- 1(2/3) No Item 1-1 Front water well Panels (up to FL + 25,800mm) 1 2 3 4 5 6 1-2 Rear water Wall Panels (up to FL + 25,400mm) 1 2 3 4 5 6 1-3 Right water Wall Panels (up to FL + 25,000mm) 1 2 3 4 5 6 7 8 9 10 1-4 Left Side Wall Panels (up to FL + 25,000mm) 1 2 3 4 5 6 7 8 9 10 Quantity Size (mm) L 1 1 1 1 1 1 18,000.00 18,000.00 18,000.00 18,000.00 18,000.00 18,000.00 W Net weight(kg) Remarks H @ Total

1,670.00 1,830.00 1,910.00 1,980.00 1,830.00 1,670.00

116.00 198.00 198.00 1980.00 198.00 116.00

4,500.0 5,100.0 5,300.0 5,500.0 5,100.0 4,500.0

4,500.0 5,100.0 5,300.0 5,500.0 5,100.0 4,500.0

1 1 1 1 1 1

17,600.00 17,600.00 17,600.00 17,600.00 17,600.00 17,600.00

1,690.00 1,840.00 1,960.00 1,990.00 1,840.00 1,690.00

166.00 263.00 198.00 198.00 263.00 166.00

3,700.0 4,300.0 4,600.0 4,700.0 4,300.0 3,700.0

3,700.0 4,300.0 4,600.0 4,700.0 4,300.0 3,700.0

1 1 1 1 1 1 1 1 1 1

11,700.00 11,700.00 11,700.00 11,700.00 11,700.00 9,320.00 10.,800.00 12,500.00 10,800.00 9,320.00

2,740.00 2,820.00 2,520.00 2,820.00 2,740.00 2,890.00 2,960.00 2,780.00 2,960.00 2,890.00

225.00 362.00 89.00 89.00 225.00 262.00 474.00 910.00 474.00 262.00

4,400.0 4,600.0 4,100.0 4,600.0 4,400.0 5,600.0 6,300.0 6,600.0 6,300.0 5,600.0

4,400.0 4,600.0 4,100.0 4,600.0 4,400.0 5,600.0 6,300.0 6,600.0 6,300.0 5,600.0

1 1 1 1 1 1 1 1 1 1

11,700.00 11,700.00 11,700.00 11,700.00 11,700.00 9,320.00 10,800.00 12,500.00 10,800.00 9,320.00

2,740.00 2,820.00 2,520.00 2,820.00 2,740.00 2,890.00 2,960.00 2,780.00 2,960.00 2,890.00

225.00 89.00 89.00 362.00 225.00 262.00 474.00 910.00 474.00 262.00

4,400.0 4,600.0 4,100.0 4,600.0 4,400.0 5,600.0 6,300.0 6,600.0 6,300.0 5,600.0

4,400.0 4,600.0 4,100.0 4,600.0 4,400.0 5,600.0 6,300.0 6,600.0 6,300.0 5,600.0

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Equipment Packing List No Item 1- Rear Hopper Panels 6 Total Replacement 7 8 9 10 2 Baffle wall panels total replacement 1 2 3 4 5 6 7 3 Long Retractable Rack soot Blower 4 Y piece for 1ry SH Coil support QTY Size (mm) L 8,330.00 8,330.00 8,330.00 8,330.00 12,300.00 12,300.00 12,300.00 12,300.00 12,300.00 12,300.00 12,300.00 13,300.0 1,800.00 Net weight(kg) Remarks @ Total 4,500.0 4,900.0 5,000.0 4,500.0 1,860.0 1,710.0 1,170.0 1,170.0 1,420.0 1,560.0 1,710.0 4,400.0 25.0 4,500.0 4,900.0 5,000.0 4,500.0 3,720.0 5,130.0 1,710.0 3,420.0 1,420.0 1,560.0 3,420.0 26,400.0 900.0

W 2,730.00 2,830.00 2,900.00 2,730.00 1,030.0 932.00 932.00 932.00 759.00 836.00 932.00 1,400.00 100.00

H 2,340.00 2,340.00 2,340.00 2,340.00 3,370.00 3,390.00 3,350.00 3,370.00 3,370.00 3,370.00 3,370.00 1,250.00 200.00

1 1 1 1 2 3 1 2 1 1 2 6 Packs 36

TABLE-1 SCOPE OF MAIN REPLACEMENT PARTS

3.7.2 ATTACHMENT 2: SCOPE OFWORKS

1) Attachment 2 (1/10)- SCOPE OF SUPPLY AND

WORKS ( General Assignment - (1/5))

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No 1

Description Insurance

Transportation Tool & Equipment for construction

Electric power for construction and office 4 Back up power 5 Water & steam for construction 6 Drinking Water 7 Compressed air & gas for construction 8 Consumables & materials for construction 9 Erection tools & equipment 10 Erection works

Provided Remarks customer contractor 0 Include for ALL risk erection, worker and third party 0 To site / on truck at sit / include unloading 0 0 0 0 0 0 0 0 As specified If required

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1) Attachment 2 (2/10)-SCOPE OF SUPPLY AND WORKS (General Assignment - (2/5)) No Description Remarks customer contractor 0 Include inspection and record *0 0 Permanent light shall be available 0 Comply with MOE specification and local requirement Comply with MOE specification

12 Receive , storage and material control 13 Temporary access road & temporary lights at work site 14 Labor's safety control and Man power control with competent supervisors & skilled workers. 15 Security , security guard and hygiene 16 Accommodation & catering for contractor 17 Communication facilities 18 Lavatory & toilet include hygiene service 19- Scrap & rubbish disposal 1 to municipal collector 19- Temporary storage for 2 slag ash and residual material 19- Classify scrap material 3 20 Leveling , reinforcement of storage , site office , working area & access road

0 0 0 0 0 0 *0 *0 0 0

Dispose at MOE designated location Dispose at MOE designated location Recyclable material dispose to MOE storage Including material and restore original condition

25

1) Attachment 2 (3/10)-SCOPE OF SUPPLY AND WORKS (General Assignment - (3/5)) No Description Remarks customer contractor 0 0 *basic design as specified *to be witnessed with customer

21 Temporary support & protection for equipment 22 Scaffolding , furnace dividing floor & monorail 23 Restoration / correction of access road, storage area & any damage of customer's properties which damaged by contractor 24 Removal of temporary facilities 25 Quality assurance , quality control , obtaining approval from purchaser & customer 26 Investigate / record for non-conformance , and corrective/ preventive action 27- Schedule control , 1 progress report & corrective action 27- Weekly reports 2 28 Coordination with customer & other contractors for schedule, quality & other general matters for the work 29 Originate & obtain
26

0 0

After completion of construction Comply with purchaser and customer requirement as original sep. Consultant to assist

0 0 Include photo, welding and NDE progress report

Provide

approval of erection procedure 30 Confirmation of erection procedure 31 Commissioning and test 0 0 perform *0

reference procedure & consultant Supply assistant by consultant

1) Attachment 2 (4/10)-SCOPE OF SUPPLY AND WORKS (General Assignment - (4/5)) No Description Remarks Customer contractor 0 0 0 0 0 0 Safety staff and facilities

32 Fire fighting equipment 33 transportation for construction employees 34 First aid facilities & nurse 35 Environmental administration system 36 Welding work including supervising , WPS & PQR and WPQT 37 Heat treatment (Pre.& post heat treatment ) 38 Hydrostatic test 0 temporary facilities 39 NDE 40 Flushing & 0 chemical cleaning

0 *0 0 0 *As specified The contractors shall supply The

27

equipment and consumable 41 Facilities for contractor's 1- site office with light, electric outlet etc. 2- desk & chair 3- cabinet & rack 4- meeting table & chair 5- refrigerator 6- fax. & telephone 7- internet line 8- computer 9- copy machine 0 0 0 0 0 0 0 0 0 0 Space 100m2

1) Attachment 2 (5/10)-SCOPE OF SUPPLY AND WORKS (General Assignment - (5/5)) No Description Remarks customer contractor 0 Include operator and maintenance 0

42 Provision of construction elevator 43 Other related work

28

2) Attachment 2 (6/10)-SCOPE OF SUPPLY AND WORKS (Temporary facilities and erection equipment - (1/1)) No Description Remarks Customer contractor 0 0

1 LAND 1-1 Land for 1-2 temporary facilities Open storage area 2 Temporary 2-1 facilities 2-2 Field office 2-4 Ware house 2-5 Changing cloth & 2-6 rest room for 2.7 labors 2.8 Parking lot 2.9 Accommodation & catering for Labors Lavatory & Wash room Communicating Facilities Others 3 Erection Tool and Facilities 3-1. Transport and Rigging 3-2. Fitting and welding 3-3. Insulation and Lagging 3-4. Painting 3-5. Air compressor 3-6. Lighting , ventilation

0 0 0 0 0 0 0 0

Include for purchaser

Refer to attachment 1-3 0 0 0 0 0 0

29

3-7. 3-8. 3-9. 3-10. 3-11. 3-12. 3-13. 3-14. 3-15. 3-16. 3-17.

Gliding machine Chain block Hoist & trolley Jack Lifting facilities for work Temporary support for work Annealing equipment Preheating equipment Non destructive testing Safety tools Other tools

0 0 0 0 0 0 0 0 0 0 0

30

3) Attachment 2 (7/10)-SCOPE OF SUPPLY AND WORKS (Temporary & storage - (1/1))

No

Description

1 Unloading at site 2 Receiving and checking of Qy & damage 3 Issue damage / missing report 4 Providing of ware 0 house 5 Safe keeping of the material & equipment 6 Control incoming & outgoing of material and equipment 7 Hand over remaining materials to the customer 8 Transportation at site 9 Others

Remarks customer contractor 0 0 0

0 0 0 0 0

Include sheet cover , skid etc.

31

4) Attachment 2 (8/10)-SCOPE OF SUPPLY AND WORKS (Source of energies - (1/1)) No 1 1-1 1-2 1-3 2 2-1 2-2 Description Electric power Power supply Transformer Distribution Facilities ( Distribution Panels , Breakers , cables .. etc. ) Water Water supply for construction Temporary Facilities (Piping , valves , tank and other necessary materials Compressed air Temporary air compressor Distribution facilities (Piping , valves ,distribution manifolds and power cable for compressor etc. ) Construction Gas Temporary receiver / supply system Distribution facilities (Piping , valves , regulators and distribution manifolds etc. ) Procurement and supply gas Remarks Customer contractor 0 Provide *0 Connect to TP TP 0 (terminal point ) 0 *Include using cost 0 Provide TP *0 0 *Connect to TP *Include using cost

4 4-1 4-2

0 0

Distribution Manifold to be placed on major working area. Acetylene / oxygen/propane / argon etc.

5. 5-1 5-2 5-3

0 0 0

Distribution Manifold to be placed on major working area. 6. others 0

32

5) Attachment 2 (9/10)-SCOPE OF SUPPLY AND WORKS (Consumable & materials - (1/2)) No Description Remarks customer contractor 0 0 0 0 0 0 0 0 0 0 0 For touch up paint If any

1 Material & consumable 1-1 Lubrication oil & Grease for operation 1-2 Flushing oil 1-3 Chemicals for acid 1-4 cleaning 1-5 Chemicals for Hydro test paint 1-6 Grout material (cement 1-7 & sand) 1-8 Temporary packing 1-9 Insulation and refractory 1-10 Consumable for refractory Dye check material others

33

5)Attachment 2 (10/10)-SCOPE OF SUPPLY AND WORKS (Consumable & materials - (2/2)) No Description Remarks customer contractor

Materials for 2 Construction 2-1 Temporary piping for 1- air / water flushing 2- air leak test 3- hydrostatic test 4- compressed air for construction 5- acetylene / oxygen Gas and distribution system 6- chemical cleaning 2-2 2-3 temporary bolt / nut 2-4 paint for temporary 2-5 facilities & protection reinforcement and 2-6 protection material for storage 2-7 area & access way sheet cover , seal cap / tape , skid .. etc. for material safe keeping 2-8 Welding electrode 1- boiler pressure parts 2- other parts 2-9 argon gas 2-10 N2 gas

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0

As specified Including piping pneumatic press. Test

Others

34

Section VI Technical Specifications Part 4

General Specification, Requirements and Procedures of Erection and Welding work

35

TABLE OF CONTENTS

4.1. GENERAL ERECTION SPECIFICATION

4.1.1- SCOPE 4.1.2- SPECIAL PROVISION 4.1.3- RECEVING, HANDLING AND STORAGE 4.1.4- PROTECTION OF MATERIAL AND EQUIPMENTS 4.1.5- HAULING AND RIGGING OF COMPONENTS 4.1.6- CONSTRUCTION LOADS , LEAVE OUT , AND TEMPORARY STEEL 4.1.7- COMPONENT ERECTION 4.1.8- BOILER HYDROSTATIC TEST 4.1.9- TEST FOR BOILER CASING AND DUCT

4.2. GENERAL WELDING SPECIFICATION/ REQUIRMENTS

4.2.1 WELDING QUALIFICATION 4.2.2 WELDING MATERIAL 4.2.3 WELDING DESIGN 4.2.4 REQUIRMENTS OF PREHEATING 4.2.5 REQUIRMENTS OF POSTWELD HEAT TREAMNT 4.2.6 WELDING SCHEDULE SHEET 4.2.7 REPAIR WELDING 4.2.8 ATTACHMENT A- attachment-3 1(1/2) - Standard welding procedure for welding of pressure parts 3 1(2/2) - Selection of welding materials B- attachment-3-2: Field welding schedule C- attachment-3-3: Control procedure of nonconforming material and components

4.3. REHABILITATION WORK PROCEDURES

4.3.1 PROCEDURE FOR REPLACEMENT OF WATER WALL 4.3.2 PROCEDURE FOR REPLACEMENT OF BAFFLE WALL PANELS

36

4.1. GENERAL ERECTION SPECIFICATION

4.1.1- SCOPE This specification describe the general requirements for erecting and field testing of the boiler installed by the contractor 4.1.2- SPECIAL PROVISION 1) references on this specification to drawings, procedures and instructions shall be considered to include those prepared by the customer supplier. The contractor shall perform all the work in accordance with the latest applicable revision to these documents. Moreover, these documents will be issued in English The contractor shall implement suitable document control procedures at the job site to comply with the requirement stated above. 2) all tolerance in drawings or standards shall be adhered to which are considered proper for the work normal concerned 3) operations associated with the installation of equipment shall be performed in accordance with the instructions for the equipment during or before erection or with this specification. 4) the mass of any vehicles used to transport equipment over the buried piping and ducts shall not exceed the relevant design load. 4.1.3- RECEVING, HANDLING AND STORAGE 1) all the equipment covered in this specification shall be received , inspected unloaded , and transferred to storage and permanent locations . All the parts , materials and components shall be received on truck at site lay down areas designated for contractor. The contractor shall prepare the record for unloading, transferring, storage and receipt of inspection. 2) contractor shall be submitted the procedure for unloading and transferring of heavy components; and shall be handled strictly and carefully in accordance with methods and procedures previously reviewed by the customers and consultant. 3) the requirement covered in this specification shall be stored and protected as required . storage and protection requirements shall apply to equipment under control of the contractor , whether the equipment is in the storage before installation has been installed , or is under installation until the issuance of the Taking Over and Acceptance Certificate .
37

Storage and protection during storage shall be made in accordance with manufacturer's recommendations . 4) the customer will assign storage areas for contractor's use at the site to the contractor. 5) the type of storage and protection shall be determined by customer and consultant's work procedure and specific instructions by the customer during performance of the work. The following storage requirements will be normally be used ; These requirements shall apply in the absence of any other specific instructions: 5.1) except as noted in this specification , outdoor storage for equipments shall be provided. 5.2) the following items require indoor storage:1- welding electrodes or filler materials after removed from the sealed container 2- all electrical control devices , except where space heaters are furnished with equipment( heaters may be connected instead of furnishing external heating , if required.) 3- instruments shipped loose 4- control panels and electronic components 4. 1.4- PROTECTION OF MATERIAL AND EQUIPMENTS 1) necessary precaution shall be taken to avoid contamination of equipment and materials during handling , storage , assembly , disassembly , and installation of equipment and materials. 2) each spool of prefabricated piping shall be capped or plugged while storage . These protectors shall not be removed until the spools are ready for final installation in the piping system. If capes or plugs in piping and fitting are missing m re-attachment of the same shall be made . 3) dust proof and watertight covers shall be put over openings of stored valves pumps and vessels. 4) during installation of equipment , opening for pipe connections , bearing holes , access openings , and open ended pipes shall be covered with dust-proof covers . Temporary covers made of plywood or sheet metal may be used to cover manholes and flanged connections , but rags , plastic , and rubber sheeting shall not be used.

38

5) during construction , electrical equipment such as instruments , racks and panels shall be protected at all time from wetting , dirt and physical damage. 6) as required , protective on the equipment specified shall be removed and/or replaced for completion of work on the equipment supplied by the customer or for functional of the equipment supplied by the customer. 4. 1.5- HAULING AND RIGGING OF COMPONENTS 1) roads The customer shall provide major access roads within the job-site. The contractor shall provide means of hauling to specified lay down areas 2) STANDARDS 2.1) assign a safety inspector to assure good rigging practice ; all such rigging . Submit any deviations from contractor's procedure to the purchaser. 2.2) the customer and consultant reserves the right to inspect handling and rigging devices and review contractor's proposed handling procedures at any time. 2.3) design , materials, procedures , tests and workmanship shall be performed in accordance with the applicable codes and standards , such as AISC , AWS , or ANSI 3) DOCUMENTATION REQUIRMENTS 3.1) before commencing work , the following shall be established for all components of each transport and rigging system: 1- original design capability 2- verification that condition under use such that original design capability is not exceeded 3.2) for heavy lifts such as the substantiate the design capabilities of transport and rigging components , except those of standard design and in commercial production , by submitting the following before the schedule lift: 1- structural design calculations , drawings , specifications and codes applied for components 2- copies of all nondestructive test reports and inspection reports 3- chemical and physical mill test reports and mature specifications; supplier's certificates for wire rope and fittings 4- welding procedure 5- welder qualification procedure and welder certifications
39

6- history of prior use of equipment 7- proof test other than those mentioned in this specification 8- detailed description of procedure to accomplish the work including rigging and handling diagrams. 3.3) for each standard design , commercially produced machine , or piece of equipment , submit the following : 1- certificate showing original design capability with factor of safety and date that rating was established A detailed inspection of machine or piece of equipment by the manufacturer or other qualified independent inspector shall be made. After the inspection , written certification shall be obtained that all pieces of equipment meet the originally designed capability. 2- before delivery to the job site , ensure by load testing that all pieces of equipment meet the originally designed capability. 4) SUBMITTALS Provide adequate drawings and calculation showing any and all loads imparted to permanent structures by contactor's handling and rigging equipment .these documents shall be described in English . 5) LOAD TEST Load testing of contractor's equipment may be requested by the costumers and consultant if no load testing is required, a visual inspection of contractor's equipment shall be conducted by the contractor to ensure the integrity of contractor's equipment. 4.1. 6- CONSTRUCTION LOADS, LEAVE OUT, AND TEMPORARY STEEL 1) any construction load and load conditions to be applied to structural steel designed and supplied by the customer shall be submitted to the purchaser 2) any construction load and load conditions to be applied to structures supplied by other shall be submitted to the customer for review by the respective structural designer. 3) provide temporary bracing as necessary for make access for omitted steel. Temporary bracing installed for omitted steel shall be properly maintained so as to provide a free and safe access to the construction area by all trades . The temporary bracing shall remove by the contractor after the contractor has installed the permanent steel that was omitted for convenience.

40

This temporary bracing shall have distinguishing marks to notify all parties of its temporary nature. 4.1.7 COMPONENT ERECTION 1 ) material , equipment and components shall be stored , protected , inspected and installed in strict accordance with the requirement of equipment manufacturers and associated drawings In addition , erection methods and procedures shall conform to acceptable good engineering practice and the requirements of applicable codes The work shall be performed in a workmanlike , economical and safe manner to ensure personal protection and avoidance of equipment damage during erection and checkout of equipment. 2) the contractor shall take necessary precaution during installation to minimize the entry of foreign matter into the boiler and auxiliary equipment The contractor shall verify that equipment and materials are thoroughly clean before assembling , erection or installing .Grease or other protective coating applied for protection of the equipment during shipment and/or storage shall be removed by the contractor using suitable solvents or cleaners that will not damage the finish of the equipment or materials . Individual equipment components that must be field assembled shall be given a thorough internal inspection. Foreign objects shall be removed and piping assemblies shall be blown out with compressed air The contractor shall be responsible for cleanliness of components 3) the contractor shall be responsible to inspect that equipment properly installed valves are properly packed , and components are complete and ready for operation . 4.1.8 BOILER HYDROSTATIC TEST 1) the customer will carry out feeding and pressurizing for boiler hydrostatic test a- safety valves shall be gagged with hydrostatic test plug by equipment manufacturer, after a successful completion of the hydrostatic test plug shall be removed . b- rehabilitate and install temporary end plates at CRP after completion of hydro test , it shall be restored to original flange connection 2) the following are general requirements for contractor for hydrostatic test

41

1- the contractor shall isolate or disconnect equipment that may be damaged during hydrostatic testing a- hanger supports shall be locked before hydrostatic testing on HRP and CRP piping system after a successful completion of the hydrostatic test locking devices shall be removed . 2- scope of the work to be done by the contractor a- inspection and witness hydro test where replaced and/or welded 4.1.9- TEST FOR BOILER CASING AND DUCT The shower test or PT shall be applied for duct and casing welding the procedure shall be prepared and submitted to the consultant and costumer.

42

4.2. GENERAL WELDING SPECIFICATION/ REQUIRMENTS

4.2.1 WELDING QUALIFICATION A. PRESSURE PART WELDING 1) All welding of pressure parts for the steam generator and associated piping welding procedure qualification , welder performance qualification , welder materials , preheat , and post weld heat treatment shall be in accordance with ASME SECT. I AND IX : ASME B31.1. 2) Welding procedure specification (WPS ) PROCEDURE QUALIFICATION RECORD ( PQR ),Welder performance qualification test procedure shell be available at the job site for review by the purchaser and customer . 3) Prior to performing the work, the contractor shall conduct welder performance qualification test at job site . 4) The identification of each welder and identification of the welding procedure (s) used for each weld shall be made available at the job site for review by the purchaser and the customer . B. NON -PRESSURE PART WELDING All welding of non pressure parts for the structural steel , duct , and casing , etc.. Shall be made in accordance with AWS D 1.1 C. OTHER Consultant and customer representative have right to call and witness welder approval test for re-confirmation although welders have been already qualified in accordance with applicable code and / or standards , he has a doubt on welder's ability . The test which may which may be called for shall be carried out the expense of the contractor .

43

4.2.2 WELDING MATERIAL A. SELECTION OF WELDING MATERIAL 1) WELDING electrodes for boiler pressure parts will supply by contractor . 2) Contractor shall provide welding electrodes in with attachment III-1. 3) WELDING electrodes and filler metal used for pressure parts are selected by the contractor and are to be indicated by contractor in welding schedule sheet supplied by the purchaser after contract . B. CONTROL PROCEDURE OF WELDING MATERIAL 1) Low hydrogen electrodes shall be dried in drying oven prior to their use if the hermetically sealed container shows evidence of damage . Immediately after opening of the hermetically sealed container or removal of the electrode from drying oven , low hydrogen electrodes shall be stored in storage ovens held at a temperature of 120 C as minimum . 2) WELDING electrodes control procedures for storage , baking and issue of electrodes shall be made available at the job site for review by the purchaser and the customer . 4.2.3 WELDING DESIGN A. WELDING PROCESS OF FIRST PASS The first pass of the butt welds and the socket welds for following pressure parts shall be deposited using the tungsten inert gas ( T/G ) welding process only . b. Boiler and piping ( integral piping ) comprehended in boiler proper c. Power piping external to boiler proper d. Fuel gas and oil piping . B.WELDING REQUIREMENTS FOR PRESSURE PARTS Welding requirements including the alignment tolerance and finished surface of welds shall be in accordance with the requirements of ASME CODE sect I or ASME B31.1 as applicable .
44

As for water wall baffle wall tubes , in addition to the above the following requirements shall be applied : 1. FIT - UP INSPECTION a) weld preparations shall be inspected with suitable gages to verify dimensions . the DC dimension of which inside diameter of welding lip is machined shall be verified in comparison with applicable fabrication drawings . b) off - set of the inner or outer surface shall be within 0.5 mm 2. BUTT WELDS OF TUBE All butt welds of the tube shall satisfy the following requirements . a) butt welds shall have a complete joint the surface of welds may be left as welded provided it is sufficiently free from coarse ripples , grooves , overlaps , abrupt ridges and valleys to avoid stress raiser . b) the meltdown of weld in GTAW welding shall be 1.6 mm in height and concavity at inside bore shall not exceed 0.5 mm in depth if any . c) weld reinforcement shall exceed 3.2 mm in height . d) undercuts shall not exceed 0.5 mm in depth and shall not encroach on the required section thickness. GTAW : Gas Tungsten Arc Welding . 4.2.4 REQUIRMENTS OF PREHEATING As general rules, welds shall be preheated in accordance with attachment - 3 1. 4.2.5 REQUIRMENTS OF POST WELD HEAT TREATMENT Welds shall be post weld heat treated in accordance with ASME sect. I and / or ASME B31.1 conditions of post weld heat treatment are selected by the contractor and are to be indicated by the contractor in welding schedule sheet ( refer to paragraph 4.2.6 ) supplied by the purchaser after contract .

45

4.2.6 WELDING SCHEDULE SHEET 1- welding schedule sheet refer to in attachment - 3-2 are prepared by the purchaser and supplied to the contractor after contract . The welding schedule sheet will indicate base material specification and welding electrode specification. So the contractor shall add the brand names of welding materials ( which supplied by contractor ) to be used , welding processes , conditions of preheating and post weld heat treatment , and requirements of NDT which contractor's scope , if applicable to the welding schedule sheet . 2- requirements of welding , heat treatment and NDE , etc. indicated in the welding schedule sheet shall be followed . 4.2.7 REPAIR WELDING 1- defects that require repair by welding shall be repaired by welding procedures and welders qualified in accordance with the ASME code sect IX . 2- any violation of the minimum drawing thickness requirements shall be rejected as a general rule . however , the contractor can refer to the purchaser for disposition as remedy . 3- nonconforming material and components shall be controlled in accordance with control procedure of nonconforming material and components referred to in attachment 3-3

46

4.2.8 ATTACHMENTS A. ATTACHMENT 3 1(1/2) STANDARD WELDING PROCEDURE FOR WELDING OF PRESSURE PARTS
No Kind of steels Carbon Steel < 460 (N/MM) Carbon Steel 460 (N/MM) 1/2Mo Typical material specification ( JIS/ASME b340,410 178a,a210a1

10

11

12

13 2

14 3

1a-1

e510 178-c

1b-A

3 4 5 6 7

ba12,13 209-T1,-T1A 205-T1,-T1A 1/20=1/2 TBA20 213-T2 Mo 10=1/2 Mo STBA21, TBA22 213-T12 1-1/40=1/2 TBA23 213-T11 Mo 2-1/40=1Mo TBA24 213-T22

1b-B 1C-B 1C-C 1C-D 1C-D

2b-B 2C-B 2C-C 2C-D 2C-D

3b-B 3C-B 3C-C 3C-D 3C-D 4C-B 4C-C 4C-D 4C-D

4C-C 4C-E 4C-E 4C-E 4C-E

5C-E

10 11

90=1Mo 90=2Mo

TBA26 213-T9 STBA27

4d-E 4C-E 4C-F 8c-C 8c-C 8c-C 8-c

4d-E 4C-E 4C-F 8C-E 8C-E 8C-E 8- c

5d-E 5C-E 5C-F 8C-E 8C-E 8C-E 8- c

6d-E 7cE 8c-E 8c-E 8c-E 8-c 7C-G 8c-G 8c-G 8c-G 8-c

12 13

90=1MoSTBA28 213-T91 No-V 18-8 1 US304,316,347 213STAILESS P304,321,347 STED 22 SUS321J1HTB 213-TP347H

8a-A 8a-A 8a-A 8-a

8b-A 8b-A 8 -b-A 8-b

8b-B 8b-B 8b-B 8-d

8c-B 8c-B 8c-B 8-c

8d-E 8d-E 8d-E 8-d

9eN -

33 SUS304J1HTB
14 25O-20NOb-N KaSUS38J1TB

10eN -

10eN -

12e

No

Holding temp

Min. holding hour according t thickness

A B C D E F G N

62525 62525 70020 70020 72020 70520 74515 NA

t12.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

12.5<t50 t/25 t/25 t/25 t/25 t/25 t/25 t/25

50<t125 2+(t-50)/100 2+(t-50)100 t/25 t/25 t/25 t/25 t/25

47

A. ATTACHMENT 3 1(2/2) SELECTION OF WELDING MATERIAL

( COMBINATTION OF WELDING PROCESS )
NO 1 2 3 4 5 6 7 8 11 12 WELDING PROCESS T/G SMAW T/G SMAW T/G SMAW T/G SMAW T/G SMAW T/G SMAW T/G SMAW T/G SMAW T/G SMAW T/G SMAW BRAND NAME NO.65G LB-26 NO.65G LB-57 HIG-70 CMB-76 HIG-90 CMA-96 HIG-100 CMA-106 HIG-9CM CM-9 TGS-9Cb CM-9Cb HIG-370 HD-370 TGS-347 RNY-16-8-2 T-HR3C or TG625 HR3C or NA112 SPECIFICATION OF WELDING MATERIALS ASME JIS SPECIFICATION SPECIFICATION A5.18 ER70S-2 Z3316 YGT50 A5. 1 E7016 Z3211 D4316 A5. 18 ER70S-2 Z3316 YGT50 A5. 1 E6016 Z3212 D5316 A5. 28 ER80S-G Z3316 YGT-M A5. 5 E7016- A1 Z3223 DT1216 A5.28 ER80S-G Z3316 YGT-1CM A5.5 E8016-B2 Z3223 DT2316 A5,28 ER90S G Z3316 YGT 2CM A5.5 E9016-B3 Z3223 DT2416 A5.5 ER505 -----------------A5.4 E505 - 16 ---------------------------------------------------------------------------A5.15 ERICR - 3 Z3334 YNICR-3 A5.11 ENICRFE-3 Z3224 DNICRFE-3 A5.9 ER347 Z3321 Y347 A5.4 E347-16 Z3221 D347-16 ------------------------------------------------

PREHEAT REQUIREMENTS
NO. A B C D E NO. A B C D E TEMPERATURE (C) MIN.100 MIN.150 MIN.200 MIN.250 NOT REQUIED HOLDING TEMPERATURE 600-650 680-720 680-720 700-740

TEMPERATURE (C) MIN.100 MIN.150 MIN.200 MIN.250 NOT REQUIED

NOTE: Preheating is not required when wall thickness of carbon steel is not greater than 12 mm.

48

B .Attachment 3-2 FIELD WELDING SCHEDULE

*** MW BLR. EQUIP
DRG NO. FOR WEL DING STR UCTUR E
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

WELDING MARK

ITEM NO.

NAME OF WELD ING PART

MATERI AL

SIZE

QUAN PER B.L.R

WELD ING METH OD

WEL DIN G ROD OR WIR E

PREHE ATING TEMP C

STRESS RE LIEVIN G

RADIO GRAPH

DE SIN G PR ESS KG/ CM G

DESI GN TMP C

HYDR O TATI C TEST PRES S KG/C MG

REMARK S

J.I.S
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

A.S.M.E . A.S.T.M
-------------------------------------------------------------------------------------------------------------

MM
-------------------------------------------------------------------------------------------

INCH
-------------------------------------------------------

FIRST RUN

AFTER 2ND RUN

NOTE :1- MARK IN THE LINE OF WELDING METHOD PRESENT MEAING AS FOLLOWS AND UNDER MAXIMUM 3- THE COOL RATE IN HEAT-TREATMENT IS 275X25c (527X0.98.4/1F H- HELIARC WELDING U- UNIONMELT WELDING 275 c ( 527 F ) PER HOUR AT THE TEMPERATURE OF 300c ( 527 F ) AND
UPPER

M- ARC WELDING H-U- FIRT RUN HELIARC , AFTER CECOND RUN : UNIOUMELT WELOING T: THE THICKNESS OF WELING PARTS 2- THE HEAT RATE IN HEAT . TREATMENT IS 220X25 / c (428X0.984/F
REMARKS and UNDER MAXIMUM 220c (428 F) PER HOR AT THE TEMPERATURE OF A.S.M.E AMERACNSOCIETY OF MECHANICAL ENGINEERSS 300c (572F) AND UPPER (T: THE THICKNESS OF WELDING PARTS ) J.I.S. Japanese INDUSTRIAL STANDARD.

49

C.Attachment-3-3 Control procedure of nonconforming material and component

1. Definition of Major Defect No repair shall be performed on defects classified as major without thorough review and documentation . the following defects are classified as major: 1.1 Surface Defect 1- typical examples of surface defects that are an inherent part of the fabrication cycle are listed below , but conditions are not limited to these examples a- removal of temporary attachments b- arc strikes c- dents on product d- marks left from jacking or chucking operations e- scars from cables or handling 2- surfaces defect will be considered as major if it extends below the minimum wall thickness 1.2 Base Metal Defect 1- typical examples of materials defects discovered during fabrication operations and caused by the manufacturer of the item are listed below , but conditions are not limited to these examples. a. laminations b- cracks c- scabs d- die marks 2- base metal defects are considered as major if they extend below the minimum wall thickness 1.3 Weld Defect 1- all cracks except crater cracks or cracks in root layer weld metal are considered as major . 1.4 Other Major Defect The following defects are considered as major: 1- any repair that involves welding after final post weld heat treatment , if post weld heat treatment is normally performed for that material 2- any repair that involves welding after hydrostatic test 3- any defects which is or may be indicative of either a fundamental material problem or a process out of control

50

4- additional weld seam(s) , miss hole (s) or burn through(s), etc ,on pressure parts caused by fabrication errors. 1.5 Exception from Major Defect Any weld defects in butt welds of baffle wall. W/W tube in a production are not to be considered as major . However , the contractor shall be responsible for documentation of such weld defects. The record shall be subjected to a review of Engineer/ purchaser's inspector and customer. 2. Disposition of Major Defect The contractor shall be responsible for documentation of major defects. Documentation of major defects shall be submitted to the customer inspector and customer or a disposition. The documentation shall include the following: 1- description of the condition 2- extent and probable cause of defect(s). 3- pertinent material and processing history 4- nondestructive examination or other means to be used to ensure that the reminder of the affected base material and welds are free of similar defect 5- method of repair 6- nondestructive examination method to be used on the repair 7- " pertinent" history is defined as only that information necessary to evaluate the adequacy of the proposed repair procedure

51

4.3. REHABILITATION WORK PROCEDURES

4.3.1 PROCEDURE FOR REPLACEMENT OF WATER WALL 4.3.2 PROCEDURE FOR REPLACEMENT OF BAFFLE WALL PANELS These Procedures to be provided by the Contractor and subjected to the approval of the Customer

52

Section VI Technical Specifications Part 5 DRAWINGS & DATA

PART 5. : DRAWINGS & DATA 5.1 DRAWINGS & DATA

The attached drawings and data are for general description of the boiler equipment boiler . 1) extent of replacement 2) arrangement of furnace upper side wall tubes 3) arrangement of furnace lower side wall tubes 4) arrangement of furnace lower front wall tubes 5) arrangement of furnace lower front wall tubes (hoppers)
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6) arrangement of furnace lower rear wall tubes 7) arrangement of furnace lower rear wall tubes (hoppers) 8) arrangement of baffle wall tubes 9) arrangement of baffle wall tubes (for erection) 10) arrangement of primary super heater tubes 11) assembly drawing of long retractable soot blower 12) soot blower expansion movement diagram & weight

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Section VI Technical Specifications Part 6 Scheduling

6) Part-6 : Scheduling
Contractor is required to submit Level one Schedule based on the following main Milestones: - The contract sign; - Mobilization for the Contractor; - Millstones activities of the Rehabilitation Works Unit 4 Shutdown The contractor is free to submit any further level of scheduling
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