MVV ENVIRONMENT DEVONPORT SEPTEMBER 2017 OUTAGE MECHANICAL WORKS SPECIFICATION.

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1 MVV ENVIRONMENT DEVONPORT SEPTEMBER 2017 OUTAGE MECHANICAL WORKS SPECIFICATION.

2 SCOPE OF MECHANICAL WORK The following list of works details the mechanical works intended to be carried out on the plant during the September 2017 outage. The list is broken down into plant system areas which then contain [in detail] the intended planned maintenance, defect and project. Where further detail is required to compile a full bid, then this should be sought from the engineers detailed in the main Invitation to Tender document. BOILER RAPPING SYSTEM. Work Order No... WK Remove the static rapping cylinders from each side of the boiler superheater section (x 26 each side). Strip, inspect and renew seals using seal kits provided. Rebuild overhauled and cleaned cylinders back onto the boiler using the setting dimensions from the Baumgarter specification. WRITTEN SCHEME INSPECTIONS. Work Order No... Various Assist with the conduct of the boiler headers inspections and the valve and equipment removal work to facilitate the Written Schemes of Examination of the pressure systems. The following equipment is to be removed and rebuilt following the examinations / tests; Boiler steam drum gauge glass unit to be replaced with new Open and clean and removal of internal gear of the Main Feed Tank Open and cleaning of the Boiler blowdown vessels Open and clean internally the Primary Air Preheater condensate vessel Open and clean internally the Secondary Air Preheater condensate vessel Open the MP Steam Manifold Remove superheated steam attemperator valves for pipework inspections Open the CHP Steam Saturator vessel BOILER & FLUE GAS PATH DOORS Work Order NoWK

3 Inspect condition of 36 in number boiler & economiser doors, renew all rope seals. Lubricate all hinge clips and securing clip with high temp grease. Consumables supplied by MVV FEEDER TABLE PUSHER Work Order No WK Clean & inspect running / guide wheels on rams and ram guides (x3). Replace wheels where necessary. Lubricate all bearings and running gear. INSTALL REFRACTORY BRICK ANCHORS TO 6M OF BOILER HEADER Work Order number WK Requirement to weld refractory brick anchors to 2x 3m of new system boiler header brickwork. Details on Drawing ZF-002-A REMOVE ALL LOW MELT POINT METALS FROM UNDERGRATE CHAMBERS Work Order number WK Requirement to remove low melt point metals from undergrate chambers. Personnel required to access chambers to remove waste material build up using Kangol hammers and hand tools Scaffold access will be provided by MVV Requires confined space entry 3

4 REMOVE PASSING STEAM DRAIN VALVES AND REPLACE WITH NEW (BUTT WELD) Work Order number WK Requirement to cut out 2 in number passing HP Steam Supply drain valves (DN25 )- P0LBA30AA566 & 567 (Butt weld valves). Contractor to supply WPS and coded welders Welders to be qualified i.a.w WPS. NDT (Radiography) required on completion of works REMOVE PASSING ECO 3 DRAIN VALVE AND REPLACE WITH NEW (DN25 FLANGE BOLTED) Work Order number WK Requirement to remove I in number passing Eco3 drain valve - P0LCA65AA554 for ECO 3 (Flange bolted valve). DN25 Flanged valve held by MVV INSTALL PROTECTION SHIELDS TO UPPER SURFACE OF ECONOMISER 1 & 2 TUBING Work Order number TBC Install protection shields on upper tube surfaces of each economiser in way of the ball shot impacts. An area of approximately 1m2 directly below each ball shot diffuser (11 Tubes at 1m) to be shielded, 8 diffusers in each economiser total area 16m2. Contractor to M/F and supply shielding material 2mm SS306 complete with holding clips. Design to be agreed with MVV EXAMINE DAMAGE TO EACH ASH CHUTE SKIRT ON ALL THREE DESLAGGERS AND REPAIR AS REQUIRED Work Order number WKWK

5 Deslaggers to be isolated and drained down prior to inspections to the ash chutes to check internally for damage. Straighten out any damage caused by mechanical impact and insert repair as required. Patch plates to be welded to all 12 Deslagger ash chutes on all four sides of each chute with 4mm stainless steel plate to a depth of 300mm Contractor to M/F and supply skirting material and patch plates Details of scope of works to be agreed by MVV See drawing PLY-BBS-MTC for ash chute details REMOVE AND SEAL THE DRAIN PLUG ON AIR RECEIVER P0QEA60BB001 Work Order number WK Air receiver to be drained. Plug 1 BSP plug removed, sealing material PTFE tape to be applied and plug replaced. AIR EJECTOR RECEIVER TUBESTACK TO BE OPENED UP FOR INSPECTION Work Order number WK Lagging to be removed to allow for access Remove in line pipework and ejector condenser end covers (bolted flanges). Will require lifting equipment to assist removal. On completion of inspection, new gaskets supplied by MVV to be used & pipework is to be replaced REQUIREMENT TO REMOVE 50% OF DRUM FURNITURE TO ALLOW ACCESS FOR INSPECTION Work Order number TBC Requirement to carry out an inspection of the condition of the steam drum nozzles etc. i.a.w the WSoE. Requirement to remove up to 50% of installed steam drum furniture as directed by MVV. Care required to prevent ingress of foreign objects by blocking drain pipework. Requires confined space access On completion of inspection, steam drum furniture to be re installed. Door seals to be replaced, supplied by MVV 5

6 REMOVAL OF 8 IN NUMBER BOILER HEADER INSPECTION CAPS, REPLACE ON COMPLETION OF INSPECTION Work Order Number WK Lagging to be removed to allow for access 4 in number boiler header caps to be cut off to allow access for internal inspection 4 in number 2/3 pass header caps to be cut off to allow access for internal inspection On completion of inspection, new caps supplied by MVV to be welded into place Contractor to provide WPS, coded welders and all welding consumables. NDT to be carried out on completion of welding. (Radiography & MPI). Boiler lagging to be replaced on completion of works LEFT AND RIGHT HAND CAMERA GUIDE TUBES REQUIRE NEW GUIDE TUBES MANUFACTURING AND INSTALLING Work Order Number WK Two in number boiler camera guides have been fire damaged. Requirement to manufacture two new guide tubes Guide tubes to be welded into position within the boiler Requires scaffold for access (provided by MVV) REMOVE AND REPLACE WITH NEW 4 IN NUMBER GRATE HYDRAULIC RAMS Work Order Number WK Scaffold required for access (Provided by MVV) Remove hydraulic cylinders installed to grate system Replace with new cylinders supplied by MVV. Will require slinging operations to remove and install. REPAIR DAMAGE NOSING PLATE ON FEEDER TABLE CHUTE Work Order Number WK Damage sustained to feeder table nosing plate due to mechanical damage and shrinkage. Requirement to cut out existing joint overlay plate and weld new plate into place on completion Material MS Plate dimensions TBC. Approx 2m x 300mm x 25mm Contractor to supply material 6

7 BHF DAMPERS - OPEN ACCESS HATCH IN FLUE DUCT AND CLEAN INTERNALLY IN PREPARATION FOR SCAFFOLDING Work Order No WK Remove access hatch (may require 2 persons) Access into flue gas path and clean internally in preparation for scaffolding (Confined Space permit will be required) BHF DAMPERS - PROVE CLEAR AND OPERATING CORRECTLY Work Order No WK Access hatch will be removed, Cleaning will have taken place and Scaffolding will have been erected. Access into flue gas path and clean and inspect dampers (Confined Space permit will be required) Prove operation of dampers BHF SOCKS AND HOPPERS INSPECT FROM BELOW FOR CONDITION/DAMAGE Work Order No WK Remove Inspection Hatches at BHF Hoppers Inspect socks from below for condition/damage. REMOVE, INSPECT AND CLEAN STRAINERS ON DE-SUPERHEATER LINES Work Order No WK /WK Unclip Insulation from around strainers. Remove Strainer lid. Inspect and Clean strainer a/r. Report any deficiencies to MVV Engineer. Replace strainer lid. Replace insulation cover. 7

8 WEAR THICKNESS CHECKS ON BALLSHOT CURVES Work Order No WKWK Remove Insulation covers around curved transport pipework. Carry out thickness measurement on back bend on 4 in number curves 2 x on Level 3 and 2 x on Level 13. Replace Insulation on completion. Produce thickness results report. REPLACE AUXILIARY COOLING WATER UNION X 2 Work Order No WK Scaffold hop-up will be erected to aid access to unions. Disconnect water supply hose Remove leaking rotating unions using hand tools. Fit new union as supplied. Replace water supply hose REPLACE MUSHROOM DISTRIBUTOR HEADS IN ECO 1 AND 2 Work Order No WK Entrance will be required into Eco 1 and Eco 2 Confined Space permit may be required. Remove existing distributor mushrooms from their position. Mushrooms should just lift off of stands. Fit new distributor mushrooms in place of removed items. PRIMARY AND SECONDARY PRE-HEATERS THOROUGHLY CLEAN ALL INTERNAL SURFACES AND STRUCTURE. RENEW DOOR SEALS. Work Order No WK Access doors will already be opened. 8

9 All primary & secondary air preheater heat exchangers to be cleaned using wire brushes and pressure washer to remove any build up of debris & dirt. Requires confined space access. All door seals to be renewed on completion of cleaning. PRIMARY AND SECONDARY PRE-HEATERS CARRY OUT THOROUGH INSPECTION OF INTERNAL STRUCTURE AND HEAT EXCHANGERS Work Order No WK Access doors will be opened and internals cleaned. Scaffolding will be erected. Carry out a thorough internal inspection. MVV Engineer may be on job site to note any anomalies. EMERGENCY DE-ASHING FLAPS OPEN, INSPECT AND CLEAN EMERGENCY DE-ASHING FLAPS AND CHUTES ON PASS 2/3 AND AT BACK OF PLANT. ALL EMERGENCY DE-ASHING CHUTES MUST BE CLEANED OUT AND FULL TRAVEL OF ISOLATING SLIDE VALVES CHECKED. Work Order No WK Open access hatches to gain access to flaps. Clean out ash chute to remove all ash. Inspect and ensure flaps operate through their full travel. REMOVE PASSING STEAM TRAPS AND REPLACE WITH NEW P0LBA30AA601 & 602 & P0MAW10AA601 (BUTT WELD) Work Order number WK Remove lagging to provide access Requirement to cut out 3 in number defective steam traps - P0LBA30AA601 & 602 &P0MAW10AA601 (Butt weld) and replace with new Contractor to supply WPS and coded welders Welders to be qualified i.a.w WPS. NDT (Radiography) required on completion of works Lagging to be replaced 9

10 REMOVE DEFECTIVE STEAM TRAP AND REPLACE WITH NEW P0LCP31AA601 FLOAT TYPE(BOLTED) Work Order number WK Scaffold to be supplied by MVV Remove lagging to provide access Unbolt and remove defective float type steam trap P0LCP31AA601 Replace with new trap Lagging to be replaced REQUIREMENT TO REMOVE ACC RELIEF VALVE FOR REFURBISHMENT AND TESTING Work Order number TBC Requirement to assist in the removal of the ACC relief valve Remove lagging to allow for access Support valve using slings and unbolt valve Remove unit using cranage provided by MVV On completion of testing unit to be replaced INSTALL REFRACTORY ANCHORS TO 19M2 OF BOILER WALL TUBING ON COMPLETION OF CLADDING WORKS Work Order number WK Requirement to weld refractory anchors to front and rear walls on completion of cladding works. Approximately 19m2 total in area. Scaffold provided by MVV Anchors to be provided by MVV 10

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