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REPAIR INSTRUCTIONS ITEM BO 001 / EE 001

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MARINE SMOKE TUBE BOILER/ECONOMIZER

Instructions for repair and refitting of damaged smoke tubes

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SAACKE MARINE SYSTEMS Tel.:+49 421 6495 138, Fax.:+49 421 6495 363,

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REPAIR INSTRUCTIONS ITEM BO 001 / EE 001

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Contents: 0 1 2 3 4 General customer information Repair technology Preparation of hot work in exhaust gas contaminated area Sealing of single smoke tubes Replacement of single smoke tubes 3 3 4 5 7

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SAACKE MARINE SYSTEMS Tel.:+49 421 6495 138, Fax.:+49 421 6495 363,

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REPAIR INSTRUCTIONS ITEM BO 001 / EE 001 0.)

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GENERAL CUSTOMER INFORMATION Safety related information are indicated by pictograms as follows: Warning! Ignoring safety information can endanger life or result in serious injury!

Caution! Ignoring safety information can result in injury to persons or damage to machinery or other materials! Take care! Ignoring safety information can result in damage to machinery or other materials!

1.)

REPAIR TECHNOLOGY Take care ! All work to be undertaken on the pressure part of the boiler body has to be checked and approved by the classification society involved prior to starting the intended work scope. For this purpose, each time work on the pressure part of the boiler becomes necessary, a detailed repair procedure has to be issued and provided to the classification society well in advance of the scheduled work period. The repair technology which is to be provided to classification society prior to starting the intended work scope has to contain the following information: All necessary steps for preparing the welding according to the procedures used and approved during newbuilding of the boiler. For these procedures, please refer to the approved original newbuilding drawing and the details therein. The intended welding mode (e.g. WIG) for each part of the welding seam (root run, middle run, final run) has to be specified in detail. Welding mode to be carefully chosen with regard to the type of damage, equipment on board and capabilities of the repair personnel. All welders who will be involved in welding the repair seams have to be certified welders with valid certificates. All welders and belonging certificates are to be listed in detail. The intended testing procedure for each part of the welding seam has to be discussed and agreed on with involved classification society in advance and has to be specified in detail.

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SAACKE MARINE SYSTEMS Tel.:+49 421 6495 138, Fax.:+49 421 6495 363,

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Suedweststrasse 13, 28237 Bremen, GERMANY email: marine@saacke.de

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REPAIR INSTRUCTIONS ITEM BO 001 / EE 001 -

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It has to be specified in detail how and when the pressure test after completion of repair work shall be executed depending on local situation and time schedule.

In any case has the repair work to be performed exactly according to the once approved repair technology. A deviation from that technology must be avoided unless agreed on with involved classification society representative or local surveyor. After completion of the repair work, the examination and approval of the repair scope will be performed by the local surveyor. If it should not be possible for any reason to have the repair scope examined, tested and approved right after completion, it might be agreed with involved classification society that the CE of the vessel might inspect and preliminary approve the proper execution of all repairs and that an authorized surveyor will attend the vessel soonest possible for final approval of the executed repairs. In any case the decisions and directions of the involved classification society will take priority over preliminary decisions and approvals.

2.)

PREPARATION OF HOT WORK IN EXHAUST GAS CONTAMINATED AREA Warning! All hot work to be executed on ocean vessels in port have to be carefully planned in accordance with local authority requirements and restrictions. Only qualified personnel which is fully capable of the intended type of hot work is to be assigned. If any hot work like welding, grinding or cutting shall be executed on exhaust gas contaminated surfaces in exhaust gas or composite boilers, the following preparation steps have to be followed to ensure that any potential harm to the persons involved will be minimised as far as possible: The water space of the boiler is to be completely drained prior to any hot work on the boiler. The funnel draught is to be minimized by closing the exhaust gas duct behind the repair zone to avoid that blistering sparks will be drawn into the silencer or funnel. All contaminated surface which will be involved in cutting or welding shall be cleaned thoroughly prior to start of work to avoid generation of hazardous vanadine pentoxide. Cutting should be executed by cut-off grinder. To assist in handling of the cutting tool, a guidance collar from plate steel should be fixed by tack-welding around the tube or on top of the plate which is to be cut. Sufficient supply of fresh air to the repair site is to be ensured at any time.
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Suedweststrasse 13, 28237 Bremen, GERMANY email: marine@saacke.de

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REPAIR INSTRUCTIONS ITEM BO 001 / EE 001 3.) SEALING OF SINGLE SMOKE TUBES

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The total number of plugged tubes should not exceed 5% of the total heat transfer surface. If it becomes necessary to exceed this amount of plugged tubes, the defective tubes must be replaced according to the procedure described in chapter 4. To seal the damaged smoke tubes, please use the tube plugs which were delivered in the spare parts scope at delivery of the boiler to shipyard. These plugs are specially made to fit the smoke tubes of the boiler. To seal damaged boiler tubes, please proceed as follows. Basic requirement for all repairs is that the boiler is completely drained and cooled down to an extent which allows entering the exhaust gas and steam space without danger: 1 The manholes of the exhaust gas chambers are to be opened and the exhaust gas inlet connection from main engine to boiler is to be sealed in order that no sparks or debris might enter the turbocharger assembly. The drain and blow down connections are to be covered. 2 - The exhaust gas inlet and outlet chambers are to be thoroughly cleaned before starting any hot work. 3 - The tube which shall be sealed is to be grinded on the surface in order to obtain a metallic bright surface for welding. 4 - After grinding, the actual inner diameter of the tube is to be checked as the tube might have been widened during mounting and grinding 5 - The tube plugs are to be reworked according to the actual tube end dimensions and are to be prepared for welding carefully in a tulip shape:

Prepare welding according to the information and dimensions (smoke tube diameter) T (plug length), t (tube plate thickness), t1 (welding seam depth), R (seam bottom contour), n (welding seam width) as given in the classification approved newbuilding drawing.

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REPAIR INSTRUCTIONS ITEM BO 001 / EE 001

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6 - Prior to placing the plug into the tube, it is essential that holes of diameter > 10 mm will be drilled or cut into the tube (one on top, one on bottom) just out of the length which will be filled by the plug.

These circulation holes will ensure that the water might circulate inside the tube once the boiler is filled again and that the tube plug will be sufficiently cooled by the boiler water during operation later on. 7 - Special care has to be taken when preparing plugs for placing into the reversing chamber of the oil fired section of the boiler. The temperature to which the plugs will be exposed might be up to 1000 C locall y. The plugs which are to be placed on the reversing chamber side of the tube shall be shortened to a length of max. t1 + 5 mm to ensure sufficient cooling of the plug material during burner operation. 8 - The tube plugs have to be placed in a tight fit into the tubes. For this purpose we recommend to tack-weld a short round bar onto the plug which can be used as mandrel. After placing and aligning the plug and after welding of the root run, the round bar can be cut off again. 9 - After completion of each run (root run, middle run and final run), it is to be checked according to approved repair technology. 10 - After completion of repair, remove all debris from the water drum and from the exhaust gas chambers, uncover the drain and blow down connections, manhole and headhole covers are to be closed and all sealings and gaskets thereon have to be replaced by new ones out of the spare parts stock. 11 - The boiler has to undergo a pressure test according to approved repair technology. 12 - All repair steps have to be done exactly according to the approved repair technology. Additional requirements of the attending surveyor, which might come up during the repair procedure, have to be followed.

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REPAIR INSTRUCTIONS ITEM BO 001 / EE 001 4.)

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REPLACEMENT OF SINGLE SMOKE TUBES If the total number of plugged tubes inside the boiler exceeds 5 % of the total heating surface, it is not allowed to seal more tubes. Any additional defective tube must be replaced by a new one to maintain the boiler capacity. Basically, all smoke tubes which have to be replaced have to be removed from the boiler by drawing out of the front (operators) side of the boiler on which the exhaust gas inlet chamber and burner are mounted. To allow drawing smoke tubes out of the boiler front side, sufficient mounting space has to be provided by surrounding construction according to below given dimensions (example shows composite boiler):
LB l

L1

L1

LB l L1

= Boiler body diameter = Boiler body length = Lifting lugs distance

- see approved original drawing - see approved original drawing - see approved original drawing

= Mounting space for tube retracting = LB + 100 mm

Given dimensions are for (partly) dismantled inlet chambers. To find out total mounting space, add inlet chamber depth from assembly drawing.

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REPAIR INSTRUCTIONS ITEM BO 001 / EE 001

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Depending on actual position of damaged smoke tubes and on the actual engine room space situation, it might become necessary to dismount a part of the exhaust gas duct before and aft of the exhaust gas boiler part. For single tubes, hovewer, a small opening can be cut into the exhaust gas inlet chamber to allow the defective tube to be drawn out without dismantling too much of the surrounding system. To exchange damaged boiler tubes, please proceed as follows. Basic requirement for all repairs is that the boiler is completely drained and cooled down to an extent which allows entering the exhaust gas and steam space without danger: 1 The manholes of the exhaust gas chambers are to be opened and the exhaust gas inlet connection from main engine to boiler is to be sealed in order that no sparks or debris might enter the turbocharger assembly. The drain and blow down connections are to be covered. 2 - The exhaust gas inlet and outlet chambers are to be thoroughly cleaned before starting any hot work. 3 - If the tube which has to be replaced was plug-sealed before, remove the tube plug with a cutting torch. 4 - Cut the tube on the rear side behind the expanded part inside of the water space so that the tube may easily be taken out of the front plate. For this purpose, reach inside the tube with a cutting torch from the exhaust gas outlet chamber. Tack weld a short angled steel bar to the short tube part to prevent it from falling into the water space once the welding seam is removed. Now grind out the existing welding seam on the rear tube plate. After the welding seam has been removed, cut the pipe end in length to take out the strength and then pull it out of the hole with the attached angled bar. Anneal with cutting torch to take the strength from the material if necessary. Take care! When grinding out the existing welding seams, take special care for the fact that the grinding must not take material from the tube plate so that the tulip shaped welding seam preparation can be executed trouble-free according to approved repair technology! 5 - Cut the pipe end carefully in length over the expanded area to take the strength out of the material so that it may be compressed during taking out of the tube. Tack weld another angled steel bar to this part of the pipe. Now grind out the existing welding seam on the front tube plate. Take care! When grinding out the existing welding seams, take special care for the fact that the grinding must leave enough material on the tube plate so that tulip shaped welding seam preparation can be executed according to approved repair technology!

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REPAIR INSTRUCTIONS ITEM BO 001 / EE 001

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6 - Remove the existing smoke tube by pushing it from the rear side of the boiler with a special steel mandrel and by pulling it simultaneously on the angled bar on the front end. Assist if necessary by annealing the tube carefully with a cutting torch. The mandrel has to be manufactured on board according to the actual smoke tube dimensions. 7 - Prepare the holes in the front and rear tube plates and in the internal reversing chamber cover plate. The holes have to be grinded and polished to metallic bright condition to ensure optimum welding conditions. The welding seam has to be prepared basically according to approved repair technology as shown in below sketch:

Prepare welding exactly according to the information and dimensions (smoke tube diameter), t (tube plate thickness), t1 (welding seam depth), R (seam bottom contour), n (welding seam width) as given in the classification approved newbuilding drawing. 8 - Remove grinding dust and debris vacuum cleaner as far as the water space is accessible through the holes of the removed tubes. 9 - Check the actually required tube length before cutting the new tube to size as deviations between design drawing and actual length may occur from time to time. 10 - To insert the new tubes into the prepared holes please follow step by step: - Prior to insertion, the tubes have to be tested for their ability to be expanded into the holes of the tube plates. This test has to be performed in a separate hole of the same size. It might become necessary to perform local heat treatment on the tubes to ensure optimum expansion ability. In any case, the tube end are to be grinded and polished to metallic bright condition to ensure best welding conditions.

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REPAIR INSTRUCTIONS ITEM BO 001 / EE 001

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- Insert the new tubes via the front tube plate. To assist in placing the tubes easily into the hole on the rear tube plate, stick a round bar of adequate length into the rear tube plate hole and lead the new tube into position by the aid of that bar. - Alignment of the tube between both tube plates has to be done in order that the projecting end at both tube plates are nearly of the same length. Take care! When aligning the smoke tubes between front tube plate and reversion chamber front plate, make sure that the rear end of the smoke tube is aligned to be flush with the reversion chamber plate! - After alignment of the new smoke tube, press the front end of the tube by angled bar to the top of the tube hole in the front plate and tack weld it in position. - Expand the rear end of the new tube into the hole in the rear tube plate. - Grind off the welding tack on the front tube end expand also the front tube end into the hole on the front tube plate. - Weld the new tube into the front and rear tube plate or into the reversion chamber cover plate according to the approved repair technology. 11 - After completion of each welding run (root run, middle run and final run), it is to be checked according to approved repair technology. 12 - After completion of repair, remove all debris from the water drum and from the exhaust gas chambers, uncover the drain and blow down connections, manhole and headhole covers are to be closed and all sealings and gaskets thereon have to be replaced by new ones out of the spare parts stock. 13 - The boiler has to undergo a pressure test according to approved repair technology. 14 - All repair steps have to be done exactly according to the approved repair technology. Additional requirements of the attending surveyor, which might come up during the repair procedure, have to be followed.

This document consists of 10 page(s)

SAACKE MARINE SYSTEMS Tel.:+49 421 6495 138, Fax.:+49 421 6495 363,

10
Suedweststrasse 13, 28237 Bremen, GERMANY email: marine@saacke.de