March 1, 2008 - portal.tmcorp.usportal.tmcorp.us/ManagerDocs/SOP/Exh_Q-Final_Job_Report.pdf · March 1, 2008 Covanta Energy PO Box 550 13500 Pond Road Delano, CA 93215-550 Attention:

Corporate Headquarters 1060 Hensley Street, Richmond, CA 94801

Ph: 510-233-2500 Fax: 510-233-2901

March 1, 2008 Covanta Energy PO Box 550 13500 Pond Road Delano, CA 93215-550 Attention: Jeff Ruoss Subject: Delano Phase II Unit 1 Refractory Outage Report Reference: Phases I & II Outage Jeff: The following is a summary of the refractory repairs performed during Phase II Unit 1 December 2007 Outage. Appendix A shows the refractory map of the replaced refractory and the recommended replacement in the upcoming outages. Appendix B shows pictures of the refractory repairs performed during the outage. I. Scope of Work Combustor Roof

1. We removed the entire combustor roof refractory back to the steel from the East Wall all the way to the vertical tubes. The total refractory removed on the combustor roof was 850 sf. See the sketch in Appendix A for a map of the refractory replaced and pictures in Appendix B.

2. We removed the existing anchoring system. 3. We performed approximately 130 sf. of steel repairs on the combustor roof. 4. We installed a new 310SS anchoring system. 5. We insulated against the steel shell with 5” of insulating gunite. 6. We installed 4” of high temperature abrasion resistant gunite with 2% 310SS needles.

North Wall

1. We removed a total of 246 sf. on the combustor North wall back to the steel. See the sketch in Appendix A for a map of the refractory replaced and pictures in Appendix B.

2. We removed the existing anchoring system. 3. We performed approximately 120 sf. of steel repairs on the combustor North wall. 4. We installed a new 310SS anchoring system.

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5. We insulated against the steel shell with 5” of insulating gunite. 6. We installed 4” of high temperature abrasion resistant gunite.

East Wall

1. We removed a total of 195 sf. on the combustor East wall back to the steel. See the sketch in Appendix A for a map of the refractory replaced.

2. We removed the existing anchoring system. 3. We installed a new 310SS anchoring system. 4. We insulated against the steel shell with 5” of insulating gunite. 5. We installed 4” of high temperature abrasion resistant gunite.

South Wall

1. We removed a total of 69 sf. on the combustor South wall back to the steel. See the sketch in Appendix A for a map of the refractory replaced.


West Wall

1. We removed a total of 45 sf. on the combustor West wall back to the steel. See the sketch in Appendix A for a map of the refractory replaced.


Vapor Space Roof

1. We removed a total of 425 sf. on the Vapor Space Roof back to the steel. See the sketch in Appendix A for a map of the refractory replaced.

2. We removed the existing anchoring system. 3. We installed a new 310SS anchoring system. 4. We insulated against the steel shell with 4” of insulating gunite on the Vapor Space side

of the expansion joint and 5” of insulating gunite on the Combustor side of the expansion joint.

5. We installed 4” of high temperature abrasion resistant gunite with 2% 310SS needles on both sides of the expansion joint.


North Wall

1. We removed a total of 105 sf. on the Vapor Space North wall back to the steel. See the sketch in Appendix A for a map of the refractory replaced and pictures in Appendix B.


South Wall

1. We removed a total of 32 sf. on the Vapor Space South wall back to the steel. See the sketch in Appendix A for a map of the refractory replaced and pictures in Appendix B.


Super Heater Walls & Roof

1. We removed a total of 250 sf. in the Super Heater walls & Roof back to the steel shell. 2. We removed the existing anchoring system. 3. We installed a new 310SS anchoring system. 4. We insulated against the steel shell with 4” of insulating gunite. 5. We installed 4” of high temperature abrasion resistant gunite.

Exhaust Duct Back Wall

1. We installed 1” of high strength corrosion resistant castable refractory against 450 sf. on the back wall of the exhaust duct.


II. Upcoming Repairs/Recommendations Based on our inspections and repairs during this outage we would recommend the following repairs during the next several outages. The recommended repairs are shown in Appendix A along with the refractory repaired during this outage. The pictures in Appendix C show several locations with potential repairs during the coming outages. Combustor North Wall As seen in the pictures in Appendix C, the refractory surrounding the repairs is down to approximately 2” of hotface. In addition, most of the wall panels are cracked and starting to loosen. It is our recommendation to start a planned replacement of the entire Combustor North wall. See the sketch in Appendix A for a map of the recommended refractory replacement. Combustor East Wall As seen in the pictures in Appendix C, the refractory surrounding the repairs (particularly around the South side repairs) is down to approximately 2” of hotface. Most of the panels are cracked and starting to loosen. In the lower section surrounding the feeders and below, the flash coating is starting to peel and exposing the failing refractory. It is our recommendation to start a planned replacement of the entire Combustor East Wall. See Appendix A for a map of the recommended refractory replacement. Combustor South Wall As seen in the pictures in Appendix C, the refractory surrounding the repairs (particularly around the East side repairs) is down to approximately 2” of hotface. In addition, most of the panels are cracked and starting to loosen. It is our recommendation to start a planned replacement of the entire Combustor South wall. See Appendix A for a map of the recommended refractory replacement. Combustor West Wall As seen in the pictures in Appendix C, the refractory along the entire West wall is cracked and pulling away from the steel. The condition of the refractory may not allow flash coating to protect it anymore. It is our recommendation to replace the entire West wall. See Appendix A for a map of the recommended refractory replacement. Vapor Space Roof During this outage, the entire Vapor Space roof was replaced from the expansion joint to the Superheater. Only a small section of the Vapor Space roof from the expansion joint to the Combustor was replaced along the North side. The multiple flash coatings on the Vapor Space roof from the expansion joint to the combustor is starting to peel exposing the failing refractory. It is our recommendation to replace the failing refractory between the expansion joint and the Combustor. See Appendix A for a map of the recommended refractory replacement.


Vapor Space North Wall As seen in the pictures in Appendix C, there are several miscellaneous locations that will be in need of repair during the next outage. The flash coating on the East side of the wall is still in tact. It is our recommendation to plan on patching as required the Vapor Space North wall. Vapor Space South Wall As seen in the pictures in Appendix C, there are several miscellaneous locations that will be in need of repair during the next outage. The flash coating on the East side of the wall is still in tact. It is our recommendation to plan on patching as required the Vapor Space South wall. Vapor Space Slant Floor As seen in the pictures in Appendix C, there are several miscellaneous locations that will be in need of repair during the next outage. The flash coating is beginning to fail. It is our recommendation to plan on patching as required the Vapor Space slant floor with a planned entire replacement in the coming outages. If you have any questions or require any additional information please feel free to call us at 510/233-2500. Thank you very much for allowing us to perform this work for you. We appreciate your continued confidence and trust. Very truly yours, J.T. THORPE & SON, INC. Tony Swager Project Manager


DELANO PHASE II UNIT I OUTAGE REPORT

APPENDIX A:

Refractory Map for Unit 1

(sketches are not to scale)


Combustor Roof (850 sf)

8” 310SS HV anchors 5” insulating gunite

4” high temperature abrasion resistant gunite w/ 2% 310SS needles

850 sf

Refractory Repaired Recommended Refractory Repairs


Combustor North Wall (246 sf)


4” high temperature abrasion resistant gunite

55 sf

145 sf

46 sf

Refractory Repaired

Recommended Refractory Repairs


Combustor East Wall (195 sf)



144 sf

3 sf

18 sf

5`sf 8`sf 6 sf 4`sf 2`sf

6 sf

Refractory Repaired



Combustor South Wall (69 sf)


4” high temperature abrasion resistant

3 sf

5 sf

9 sf

45 sf

7 sf

Refractory Repaired



Combustor West Wall (45 sf)



4`sf 12 sf

5`sf

3`sf

1`sf

15 sf

5`sf

Refractory Repaired



Vapor Space Roof (425 sf)

Combustor Side of Expansion Joint Vapor Space Side of Expansion Joint

8” 310SS HV anchors 7” 310SS HV anchors 5” insulating gunite 4” insulating gunite

4” high temperature abrasion resistant gunite 4” high temperature abrasion resistant

425 sf

Refractory Repaired Recommended Refractory Repairs


Vapor Space North Wall (105 sf)



Misc.

Patches

80 sf 25 sf

Refractory Repaired



Vapor Space South Wall (32 sf)



Misc. Patches

3 sf

29 sf

Refractory Repaired




APPENDIX B:

Unit 1 Refractory Pictures


COMBUSTOR ROOF STEEL REPAIR


COMBUSTOR ROOF REFRACTORY


COMBUSTOR NORTH WALL


COMBUSTOR EAST WALL


COMBUSTOR SOUTH WALL


COMBUSTOR WEST WALL


VAPOR SPACE ROOF


VAPOR SPACE NORTH WALL


VAPOR SPACE SOUTH WALL



APPENDIX C:

Unit 1 Potential Repairs


POTENTIAL REPAIRS COMBUSTOR NORTH WALL


POTENTIAL REPAIRS COMBUSTOR EAST WALL


POTENTIAL REPAIRS COMBUSTOR SOUTH WALL


POTENTIAL REPAIRS COMBUSTOR WEST WALL


POTENTIAL REPAIRS VAPOR SPACE ROOF

POTENTIAL REPAIRS VAPOR SPACE NORTH WALL


POTENTIAL REPAIRS VAPOR SPACE SOUTH WALL

POTENTIAL REPAIRS VAPOR SPACE SLANT FLOOR

Documents

March 1, 2008 - portal.tmcorp.usportal.tmcorp.us/ManagerDocs/SOP/Exh_Q-Final_Job_Report.pdf · March 1, 2008 Covanta Energy PO Box 550 13500 Pond Road Delano, CA 93215-550 Attention: