Kribhco Report

ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS
TABLE OF CONTENTS
DESCRIPTION PAGES
1.
Acknowledgement 2
2.
Certificate 3
3.
Executive Summary 4-14
4. Introduction (History of the Plant) 15-16
Intent of Study 17-38

5.
Remaining Life of Boiler Components 39-40
6.
Run Repair Replacement, Five year 41-45
7.
action Plan, & Conclusion
8. NDT & DT Survey report 46-214
9. Equipment Used 215-218
10. Team Deployed 219
11. Abbreviation 220
12. site photographs 221-225
Residual Life Assessment study of HRSG Page No. 1

Report No. F136/RLA/KRIBHCO/BLR1/07/2017
ACKNOWLEDGEMENT
We Energo Engineering Projects Limited extend our sincere thanks to the

authorities of Kribhco Shyam Fertilizersfor entrusting RLA Study job for
HRSG # 1.
Energo Engineering Projects Limited, New Delhi carried out Residual Life
Assessment of HRSG # 1 (Regn. No. UP- 5318) at Kribhco Shyam Fertilizers
as per IBR 391 A (table 1) & Scope of work of Kribhco Shyam Fertilizers.
We sincerely thank Director of Boilers , Uttar Pradesh for the valuable

guidance and his approval to conduct the RLA study.
We also appreciate the courtesy, help and co-operation extended by the

Engineers & Staff of Kribhco Shyam Fertilizersand also sharing of their
operational experiences during course of RLA Study.
Dheeraj kumar Choudhary

Manager -RLA

CERTIFICATE
Certified that the NDT on HRSG # 1 (Reg.no. UP- 5318) at Kribhco Shyam
Fertilizers has been conducted meeting the requirement of IBR 391(A) table
-1 and the requirements of Kribhco Shyam FertilizersWork Order
No.:KSFL/SPN/M-O/S/6000201/PD/85000736 Dated 01/08/15.
All remarkable findings on Visual Inspection, Cold walk through survey and
NDT were recorded jointly with Kribhco Shyam Fertilizersin the form of Daily
reports copy of which were furnished for immediate action if any, these are
now furnished in duly typed form in the Final Report No.
F136/RLA/KSFL/BLR1/07/2017 show the boiler is fit for steaming at design
parameter. Further final recommendations have been furnished after chemical
analysis of Drum, metallurgical analysis, destructive test of tube samples in
laboratory.
For Energo Engineering Projects Limited
Dheeraj Kumar Choudhary

Manager-RLA

EXECUTIVE SUMMARY
Objective of the study is to assess the present condition of various pressure

parts and components of the Boiler and to estimate the Remaining Life of
these components, so that immediate corrective action is taken and further
plan for next Six years could be recommended.
The intent for the Residual Life Assessment Study of Boiler Pressure Parts is
to Inspect and test the various Pressure Parts of the Boiler as per IBR 391(A)
Table-1 and as per scope of study desired by Kribhco Shyam Fertilizersin
their order and agreed by EEPL.
Following Non-Destructive Tests were carried out during site RLA Study.
1. Visual Examination
2. Dye-Penetrant Test
3. Magnetic particle inspection
4. Ultrasonic test
5. Ultrasonic Thickness Measurement
6. Dimensional Measurement
7. In-Situ Metallography and Replication for lab study
8. In-Situ Oxide Scale Thickness Measurement
9. Hardness measurement

Executive summary Table
Sr. Boiler Tests

No. Comp- Conducted Findings / Observation Remark Six
onent
Visual inspection carried out at drum internally Satisfactory Re
01. Drum Visual and externally exposed area. Magnetite layer -RLA
Inspection found in satisfactory condition. Drum internal Study
found in satisfactory condition. Thin layer of will
corrosion found on the outer surface. be
DPT Dye Penetrant Test carried out at all Satisfactory carrie
attachment weld joints, circumferential & d out
longitudinal weld joints. No surface defects after
observed. Six
MPI MPI carried out at circumferential weld joints & Satisfactory year
longitudinal weld joints. No surface &
subsurface defects observed.
UFD Ultrasonic flaw detection test carried out at Satisfactory
circumferential and longitudinal weld joints,
safety valve stub joints and drum ligament
joints. No remarkable indication observed
UT-T Thickness measurement carried out at shell Satisfactory
and dish end.
Detailed enclosed
Internal Internal Diameter carried out at drum Satisfactory
Diameter Detailed enclosed
RPL In situ metallogaraphic carried out at. Microstructur
WM: Microstructure show predominent e show the
structure of pearlite & farrite degradation
PM: Microstructure show predominent between
structure of pearlite & farrite. No crack or level-I &
cavitation found. level-II
Hardness WM:154 Satisfactory
PM:122
Deposit Deposit sample collected for lab test. detailed
sample report
Analysis enclosed.
Satisfactory
10.Econo VI In visual inspection carried out at Satisfactory Re -RLA

03. miser Economiser tube, No major abnormality Study
tube observed. will be
carried

UT-T Thickness measurement carried out at Satisfactory out after
Economiser tube. Six year
Detailed enclosed
OD Outer dimension carried out at Economiser Satisfactory

tube.
Detailed enclosed
13.Evapor VI In visual inspection carried out at Satisfactory

0 ator Evaporator tube, No major abnormality
tube observed.
04. UT-T Thickness measurement carried out at LP Satisfactory

Evaporator tube.
Detailed enclosed
OD Outer dimension carried out at LP Satisfactory

Evaporator tube.
Detailed enclosed
16.De VI Visual inspection carried out at De Satisfactory Re -RLA

Superh Superheater exposed area , no abnormality Study
06. eater observed. will be
carried
UT-T thickness carried out at De Superheater. Satisfactory out after
Detailed enclosed Six year
OD Outer dimension carried out at De Satisfactory

Superheater
Detailed enclosed
19. RPL/HB In situ metallogaraphic carried out at Microstructur

WM: Microstructure show predominent e show the
structure of pearlite & farrite degradation
PM: Microstructure show predominent between
structure of pearlite & farrite. No crack or level-I &
cavitation found. level-II
WM:134,143
PM:114,123
UT UT carried out at circumferential weld joints. Satisfactory

No Remarkable indication observed.
DPT DPT carried out at circumferential joints. No Satisfactory

surface crack observed.

swell swell measurement in the permissible limit Satisfactory
measurem
ent
23.Main VI In visual inspection no major abnormality Satisfactory Re -RLA
07. Steam observed on main steam line. Study
Line DPT DPT carried out at circumferential weld Satisfactory will be
joints & all accessible stub joints. No surface carried
defect observed. out after
MPI MPI carried out at circumferential weld joints Satisfactory Six year
& all accessible stub joints. No surface &
subsurface defects observed.
UTD Ultrasonic flaw detection test carried out at Satisfactory
circumferential weld joints. No remarkable
indication observed.
UT-T Thickness measurement carried out at main Satisfactory
steam line.
Detailed enclosed
OD Outer diameter carried out at main steam Satisfactory
line
Detailed enclosed
Hardness Hardness measurement carried out at main Satisfactory
steam line
WM:132,141
PM:111,120
30. RPL In situ metallogaraphic carried out at Microstructur
e show the
WM: Microstructure show predominent degradation
structure of pearlite & farrite between
PM: Microstructure show predominent level-I &
structure of pearlite & farrite. No crack or level-II
cavitation found.
swell swell measurement in the permissible limit Satisfactory

measurem
ent
32.SH VI Visual inspection carried out at SH header Satisfactory Re -RLA
header tube. No erosion observed. Study
11. tube OD Outer diameter measurement carried out at Satisfactory will be
SH header tube. carried
Detailed enclosed out after
UT – T Thickness measurement carried out SH Satisfactory Six year
header tube
Detailed enclosed
UT-O In situ oxide scale measurement carried out Satisfactory
at Super heater tube.
UT-O< 150 micron
36. VI Visual inspection carried out at Super heater Satisfactory Re -RLA
tube. No erosion observed. Study

Super OD Outer diameter measurement carried out at Satisfactory will be
12. heater Super heater tube. carried
tube Detailed enclosed out after
UT – T Thickness measurement carried out at HP Satisfactory Six year
HT Super heater tube
Detailed enclosed
UT-O In situ oxide scale measurement carried out Satisfactory
at HP HT Super heater tube.
UT-O<150micron
40.Feed VI Visual inspection carried out at Feed water OK Re -RLA

water line. No major abnormality observed. Study
line will be
MPT MPT carried out at circumferential weld OK carried
joints of Feed water line. No surface and out after
19. subsurface defect observed five
DPT DPT on circumferential joints & all OK year
accessible . No surface defects observed.
UT-S Ultrasonic test carried out at circumferential OK
weld joints of Feed water line. No
remarkable indication observed.
UT-T Ultrasonic thickness carried out at feed Satisfactory
water line
Detailed enclosed
OD OD carried out at feed water line Satisfactory
Detailed enclosed
Hardness Hardness measurement carried out .
PM=115,126
41.Boiler VI Visual inspection carried out at Boiler OK Re -RLA
21. Structu Structures. No major abnormality observed. Study
res will be
42.Boiler VI Visual inspection carried out at Boiler OK carried
22. Expans Expansion. out after
ion No major abnormality observed. five
43.Boiler VI In visual inspection no major abnormality OK year
23. Valves observed on Boiler Valves & safety valves
&
safety
valves

INTRODUCTION
Kribhco shyam fertilizers limited shahjahanpur appointed Energo Engineering

Projects Limited (EEPL) for carrying out the RLA Study vide there LOI No.
KSFL/SPN/M-O/S/6000201/PD/85000736 Dated 01/08/15. EEPL has carried
out all the tests as per the scope and wherever required followed standard
procedures as per IBR Guidelines.
Remaining Life Assessment (RLA) of HRSG boiler Unit # 1 (100MTPH), KSFL

Shahjahanpur was required as part of renovation & modernization activities.
As almost all the pressure part components of the boiler were to be assessed,
this activity required a multi-disciplinary approach. Various testing methods
were utilized & experts from a number of fields were involved.
Site activity commenced on 05/7/2017 and completed on 08/7/2017. All the

data / documents required for analysis and recommendation for the
completion of final report were collected during site activity.
This final report includes major findings of the RLA study carried out on Boiler
(100MTPH) of KSFL, Shahjahnpur . Photographs and micrographs along
with expert comments and recommendations have been included in this final
report.

Operational History
The Kribhco Shyam Fertilizers HRSG # 1 is of Thermax Babcock & Wilcox

Ltd make of steam generation capacity 100 T/Hr Super Heated Steam at 115
kg/cm2 Pressure and 515 0C Temperature.
The Boiler was commissioned on 1992 & has already clocked 1, 00,000
working hours.
Type of Unit : Natural Circulation

Steam Flow : 100 MT/hr of Steam

INTENT OF STUDY
The objectives of Residual Life Assessment Study of THERMAX BABCOCK
& WILCOX LTD PUNE make HRSG # 1 Pressure Parts (Reg. No.UP-5318) of
Kribhco Shyam Fertilizersare as follows :
1. To establish the present condition of Boiler Pressure Parts.
2. To project the remaining useful life of Pressure Parts.
3. To provide realistic and practical recommendations for Run,
Repair and Replace if required.
4. To provide steps for reliable and safe operation.
5. To reduce the forced outages due to failures of pressure parts
and to achieve maximum boiler availability.
The RLA Study was carried out as per the guidelines of Indian Boilers
Regulation Clause 391 (A), (a) table 1 and also the detailed specific
requirements of Kribhco Shyam Fertilizers Vide their Work Order No.:
KSFL/SPN/M-O/S/6000201/PD/85000736 Dated 01/08/15

EEPL APPROACH & RLA METHODOLOGY
NOTE ON DAMAGE MECHANISM OF STEAM GENERATOR

COMPONENTS
Material selection in HRSG boiler construction varies within the boiler,

depending on duty requirements, economics and availability of a component
in the sizes required. Boiler tubes are seamless, finned, extruded tubes and
vary all the way from carbon steel..
Although tubes and pipes have some unique problems of their own, two
fundamental and common factors that dictate material selection are creep
strength and resistance to oxidation at high temperatures.
Boiler-Tube Failure Mechanisms
Failure of boiler tubes is the foremost cause of the forced boiler outages. The
major failure categories in boiler tubes are listed as below.
 Stress – Rupture.
 Short-term overheating.
 High-temperature creep.
 Dissimilar-metal welds.
 Water-Side Corrosion.
 Caustic corrosion.
 Hydrogen damage.
 Pitting (localized corrosion).
 Stress-corrosion cracking.
 Fatigue.
 Vibration.
 Thermal.
 Corrosion.
 Lack of quality control.

 Maintenance cleaning damage.
 Chemical excursion damage.
 Material defects.
 Welding defects.
A. Stress-Rupture, and Thermal Fatigue are specifically related to the

high temperature environment.
Failure by stress-rupture mechanisms are encountered predominantly
in HT super heater .where tube operating temperatures are in creep
range. However, stress rupture also can occur in LP tubing if abnormal
heat transfer conditions result in an increase in tube operating
temperature.

The significant subcategories of stress-rupture failure mechanisms are:
a) Short-Term Overheating.
b) High Temperature Creep.
 Short-Term Overheating: -
A short-term-overheating failure is one in which a single incident or a
small number of incidents exposes the tube steel to an excessively
high temperature (hundreds of degree above normal) to the points
where deformation or yielding occurs. These abnormal conditions are
created by following circumstances:
a) Internal blockage of the tube.

b) Loss of coolant circulation or low water level.
c) Loss of coolant due to an upstream tube failure.
In general short term over heating failures involve considerable tube

deformation in the form of metal elongation and reduction in wall
area or cross-section. Such failures are often characterized as
having knife-edge fractured surfaces. Wall thinning and local bulging
precede the actual fracture, because the edge of the material is
reduced at higher temperatures.
 High Temperature Creep: -

Boiler tube failures can result from high temperature creep of the HT
super heater . Metal degradation and permanent deformation will
occur with time depending on actual temperature and stress levels. If
temperature and stress exceed design selection values, the tube
steel will exhibit a higher creep rate and will fail earlier than
expected. Predominant location for creep failure:
a. Just prior to a charge to a higher grade of steel.
b. Just prior to a HPHT outlet header, where the tubing and steam
temperature are the highest.
High temperature creep failures some times are called 'long term' or
extended overheating failures. Such a failure results from a relatively
continuous extended period of slight overheating (different between
design and actual operating) a slowly increasing level of temperature
or stress, or accumulation on several period of excessive overheating,
the creep damage occurs along the grain boundaries of the steel
Metal degradation and permanent deformation will occur with time depending
on the actual temperature and stress levels. If the temperature and stresses
exceed design selection values, the tube will exhibit a higher creep rate and
will fail earlier than expected. Theses abnormal conditions are created by the
following circumstances:
a) Internal restriction of tube coolant flow by scale, debris, or

condensate.
b) Reduction of heat transfer capability due to internal (steam-side)
surface oxide scales or chemical deposits.
c) Blockage or lining of boiler gas passage.
d) Operation of a tube material at higher than allowable temperature.
e) Increase in stress due to wall thinning.
High temperature creep usually results in a longitudinal fractured in the

heated side of the tube. Prevention of the high temperature creep failure
involves keeping the tube metal stress and temperature with in the capability
of the tube material.
Boiler tube failure can also result from high temperature creep at or
adjacent to supports or attachment welded to HT super heater tubes.
a. Differences in thermal expansion properties.
b. Restraints to uniform tube expansion.
The finned attachment also can transfer more heat to the tube and result in
higher metal temperature .
Prevention of high temperature creep failure involves keeping tube metal
stress and temperature within the capabilities of tube material.
B. Water Side Corrosion: -

Boiler-tube failure due to corrosion can result from prolonged
accumulation of water in the header & tubes.
 Caustic attack: These occur when there is excessive deposition on
ID tube surfaces. This leads to diminished cooling water flow in
contact with the tube, which in turn causes local under deposit boiling
and concentration of boiler water chemical.
 Hydrogen damage: High temperature exposure of carbon and low
alloy steels to high-pressure hydrogen leads to a special form of
degradation known as hydrogen damage. In contrast to hydrogen
embrittlement, which degrades toughness at low temperature and
imposes restriction on start up and shut down procedures, hydrogen
damage leads to a degradation of material properties at the
operating temperature. Hydrogen damage is basically a
decarburization reaction. If the cracks occur internally i.e. methane
is unable to escape, forms bubbles and leads to permanent internal
damage. Reaction can be written as;
2H2+C→CH4
Where the carbon is in the form of carbides, grow under methane
pressure, and link up to form fissures and cracks.
Hydrogen damage is most commonly associated with excessive
deposition on ID tube surfaces, coupled with a boiler water low P H
excursion. Water chemistry is upset, such as what can occur from
condenser leaks, particularly with salt water cooling medium and leads
to acidic (low PH) contaminants that can be concentrated in the
deposit.
 Pitting: Oxygen pitting occurs with the presence of excessive oxygen
in boiler water. It can occur during operation as a result of in leakage
of air at pumps or failure in operation of preboiler water treatment
equipment, This also may occur during extended out of service
periods such as outages and storage , if proper procedures are not
followed in lay up.

 Stress corrosion cracking: This type of corrosion is associated with
super heater materials and can lead to either transgranular or
intergranular crack propagation in the tube wall. It occurs due to
combination of high tensile stresses & corrosive fluids are present.
C. Fatigue
Fatigue is the result of cyclical stresses in the component. Mechanical
fatigue associated with external applied stresses, may be associated with
vibration due to flue gas & uneven expansion of component.
D. Lack of quality control
Lack of quality control comprises of feed water chemistry, mechanical
damage of tube during installation & overhauling , poor welding of joints,
alignment of drums & headers to ensure proper assembly of tubes. Tubes
should be free to expand during operation to avoid any buckling.
Header Damage Mechanisms

A header is essential a pipe to which tubes are welded, spaced either axially
or circumferentially. The spacing between tubes is known as ligament.
Creep at weldments and thermal fatigue in header body ligament has
emerged as principal damage mechanism. Initial sign of creep related stress
often appears at weld. Although weld related cracking is generally
detectable and repairable and it does not have as great impact on the
overall component life as does header body base metal deterioration, it is
important from a life assessment point of view for the following reason.
a) Because of weld failure in the body, they can provide an index of creep
damage
and remaining life in the base metal.
b) Failure of weld at crucial and multiple locations may constitute the end of
life header.
a) The need for frequent weld repair may prove uneconomical and justify
retirement of headers.
2.0 APPROACH FOR RLA STUDY

Each particular life extension project demands a dedicated study
program, depending upon the details of the plant involved and the
specific requirements of the owner of the plant. The underlying
methodology and procedure adopted by EEPL is based on the
approach of selective, comprehensive range of analytical, predictive
and investigative techniques and the most accepted norms such as:
A Study of the plant maintenance and operating records in

conjunction with plant design data.
B Identification of problem areas and deficiencies in the boiler by
walk though survey and interaction with the plants operating personnel.
These are subsequently investigated in order to recommend the
remedial measures required to ensure maximum future plant
availability.
C Creep life spent is one of the major criteria governing the
suitability for further service of high temperature and highly stressed
components such as those present in high temperature boiler
components. The approach in determining the remnant life of creep
affected components on the basis of microstructure examination is
fairly revealing and widely accepted.
Application of replicas for remnant life estimation process has the

following background:
The life of exposed components is limited by creep strain when the
straining capability of the material is exhausted, it will form cracks and
fail the high temperature component, showing that operational cracks
in these components are generally preceded by microscopic grain
boundaries cracks and cavitations. Such microscopic cracks first
formed as cavities on the grain boundaries of the outside surface of the
components several years before the final failure of the components
will occur. Neubauer and Wedel method of interpretation of creep
damage and prediction of remnant life or setting inspection interval has
been widely accepted.
When no creep pores are seen, but only spheroidized carbides are
observed then creep damage is considered as less and the next
inspection is needed after about 5 years. Similarly if isolated creep
pores and chains are seen the inspection is necessary after 5 years. If
grain boundary micro-cracks are observed a repair or replacement
within 6 months. According to Neubauer if micro-figures are noticed in
microstructures / replica an immediate replacement is desirable.
A graph showing creep life assessment based on cavity classification is
given below:
1. Isolated cavities 2. Oriented cavities

3. Micro cracks observed 4. Macro cracks
Standard Life Estimation Replica (Source: Standard Metallurgy Book)

They characterized cavity evolution in steel at five stages i.e. undamaged,
isolated cavities oriented cavities, linked cavities (micro cracks), and macro

cracks. They also formulated the recommendations corresponding to the
different stages of cavitations. For undamaged no remedial action would be
required. For Class – 1 consisting of isolated cavities Re inspection within 5
years would be required. For Class-2 damage, consisting of oriented cavities,
re-inspection within 1½ to 3 years would be required. For Class-3 damage,
repair or replacement would be needed within six months. For Class-4
damage, immediate repair would be required.
Expended life fraction of steels.
trem = texp x (1/x-1)

The expended life fraction is given in table below:
Level of Class of Microstructure Expended life
degradation Structural features fraction (x)
Classification
Level -I Un-damaged Ferrite & pearlite 0.12
Level -II 1 Isolated cavities 0.46
Level -III 2 Oriented cavities 0.54-0.64
Level -IV 3 Limited cavities 0.84
(micro cracks)
Level -V 4 Macro cracks 1.00
D. Study of Pressure part carried out by NDT inspection as Visual

inspection, Dye Penetrant Test, Magnetic Particle test, Ultrasonic flaw
detection, Fibroscopy , dimension measurement, parent metal
inspection, oxide scale measurement , hardness test & mechanical
strength , chemical analysis of tubes & estimate the remaining life of
boiler.
3.0 METHODOLOGY ADOPTED
3.1 In general approach adopted by EEPL is in line with relevant

sections of IBR. The NDT examination was carried out by qualified /
certified personnel.
After the comprehensive visual plant inspection by a team of specialist.

EEPL engineers, the NDT inspection schedule was developed for
boiler. The types of tests were planned in consultation with the client
and meeting the requirements.
3.2 The Remaining Life Assessment is performed for components,

which are operating at or above 450° C, since they undergo such
changes in properties, which can be co-related with time. Non-
destructive tests, such as replication enables assessment of
accumulated damage and consequently the remaining life.
3.3 Some important components of Boiler such as Economizer HP

& LP Drum, etc, which are not operating in creep zone, are also
examined for their present condition. Assessment is based on finding

of nondestructive tests, performed at locations decided on basis of
visual inspection, operating history and failures experienced in past.
3.4 Extensive in situ metallography was carried out also Replicas

were taken to examine microstructure of various critical
components. Microstructure changes are most important
assessment technique for high temperature components. These
norms are developed by Nuebauer and Wedel have now become
industry standard as per 2.0(c) above.
Procedure for Life Assessment: -

The residual life assessment relies upon determining accurately three kinds of
information about a component:
a) Current degree of damage (due to past operation).
b) Rate of damage accumulation.
c) Degree of damage required causing failure.
1. If an estimate of current damage, along with a rule for damage
accumulation and failure criterion is known, then component residual life
can be assessed. To make these assessments, the general methodology
and guide lines outlined in EPRI documents have been followed.
2. Before describing the various phases involved in analytical estimation
of residual life of Power Plant components, the entire procedure may be
divided in to a few major steps. These steps provide a systematic
approach to the solution and are as follows:
I. Identification of critical components.
II. Data collection for damage computations.
III. Stress computations.
IV. Damage computations.
V. Crack growth analysis.
A brief outline of the procedure that is adopted at each one of these steps
is furnished in the following sections.
I. Identification of Critical Components: -

Critical components are those which are subjected to high temperature /
stress and those which have chronic failure history. For example, high
pressure piping is subjected to piping stress analysis to identify critical
areas for NDT.
II. Data Collection for Damage Computations: -
The basic data required for damage computations are: -
a. Plant Operational Data: -

This includes number of hours of steady operations and number of
various start ups, such as hot start, warm start and cold starts. If the
load changes are from past history, it is also noted down with
amplitudes and time duration.
b. Geometrical Data of Components: -
The relevant geometrical parameters such as thickness, dimensions
and clearances of the components are obtained from the production /

fabrications drawing which are essential for the stress / strain
computations.
c. Material Property Data of the Components: -
The data required for stress and strain computations such as modulus
of elasticity, poisson’s ratio, yield strength, ultimate strength are
collected. In case such data are not available for the material under
consideration and specifically over a range of desired operating
parameters, suitable assumptions are made by considering equivalent
material and using parametric relations, datas are derived from table or
curves available in the literature / materials handbooks. Using certain
parametric relations (for example, Larson-Miller Parameter for creep
rupture time) most suitable for such materials, properties at desired
operating parameters are derived from data collected.
II. Stress Computations: - This task is essential for the creep fatigue
and crack growth analysis of critical components.
a. Stress Computation for Creep.
a. Stress Computation for Fatigue.
IV. Damage Computations: -

a) This is pertaining to life corresponding to crack initiation which is a
function of the total cumulative damage and extrapolating this to find
out how long it would take to attain a present terminal value of
damage.
b) Cumulative damage of critical components that are subjected to
steady state and transient stress can be estimated from knowledge of
past usage, operating stresses and material properties. Damage is
defined as the fraction of life that has been expended over a certain
period of time and a certain number of cycles consisting of start-up,
shut down and load changes operations. Total cumulative damage, Dt
is defined as the linear sum of damage due to creep and low cycle
fatigue:
Dt = Dc + Df
ti ni
Dt = ∑ ------ + ∑ ------
Tf Nf
Where ti and ni are actual time and cycles, respectively and Tf and Nf
are the time period in hours to cause creep rupture and number of
cycles to cause fatigue crack initiation respectively at the same stress
level and temperature ti and ni.
c) Stresses computed to obtain the creep rupture time (Tf) in hours for
the material used. Similarly the stress or strain range computed to
derive the number of cycles to failure / crack initiation (Nf). Thus the
damage due to creep and fatigue of a critical component is obtained
from which the residual life may be evaluated.
d) Stationary thick walled components which are subjected to stresses
due to sustained loads and temperature gradients do not fail
immediately even if creep rupture criterion is satisfied. It is the
experience of the past which indicate that the end of predicted creep
rupture life as per damage rule, a crack will initiate at the critical
location, propagate and eventually cause failure. In this case,
substantial portion of the life of the component is exposed is spent in
crack propagation, and creep rupture criterion based on damage
calculations would not sufficient. In such cases, total life of component
is expressed as a sum of life expended and life remaining and which in
turn can be expressed as a sum of life expended and life remaining
and which in turn can be expressed as sum of crack initiation life and
crack propagation life.
e) In this, the crack initiation is estimated by damage mechanics
calculations (as described above) and crack propagation life is
estimated using Crack Growth Analysis based on fracture mechanics
approach.
f) Crack growth calculations are performed essentially on stationary
components containing a real crack (as detected during inspection) at
a critical location or an assumed initial crack of maximum size that can
not be detected by conventional non-destructive examination (NDE).
The time required for such a crack to grow from present size or
assumed size to a present limiting value (percentage of critical crack
length) gives an estimate of propagation life. Valve bodies, steam
chests, casing of turbines, drums and high energy piping are examples
of stationary components which fall under component category for
crack growth analysis.
f) Crack growth analysis is applicable under following conditions:

i. Microstructure based on ND Metallography reveals that the
component has reached a stage to contain link up of creep cavities
or micro-cracks.
ii. Single large crack is present (clustering of proximate micro cracks
can be done to simulate their effects through a single crack).
iii.Crack is present in a stress zone that experiences a tensile stress
field around the crack tip (check whether the crack is located in a
potentially tensile stress zone).
iv. Crack growth rate data is available for the prevailing damage
mechanism (Viz., fatigue, creep, creep-fatigue)
V. Crack-Growth Analysis-Procedure
Stepwise procedure for remaining life estimates using crack growth
analysis is furnished below:
a.Collect data on crack size (length-a), location and orientation from
NDE (if available) or data may be assumed as indicative above. The
corresponding stress (Л) evaluated is the principal (maximum) tensile
stress normal to direction of crack opening.
b.Find shape factor Q for the crack geometry and fracture toughness
Klc for component material.
Q Klc
c. Find critical crack length using ac = [----- + ------]2
1.21Л σ
d. Set a factor of safety (fs) on ac and obtain a working limit a r: ar =
ac /fs.

e. Criteria for material to be rejected, if a is greater than or equal to af,
otherwise perform crack growth analysis based on data for material on
fatigue, creep and combined creep-fatigue growth rates viz., da/dN,
and da/dt respectively.
f. An incremental analysis is performed for the crack to grow from size-

a to the next higher value say-a1 on application of principal tensile-
stress (σ).
Knowing da/dN and da/dt and (a1-a), the no. of cycle / duration through
which the particular location in the component undergoes a certain cyclic /
steady stress can be determined for the crack to propagate from a to (a 1 –
a), the no of cycles / duration through which the particular location in the
component undergoes a certain cyclic / steady stress can be determined
for the subsequent stages, say from a 1 to a2 to a3 and so on. These
computations are repeated until the crack length – a attains the terminal
value i.e., af. The corresponding no. of cycles/time duration is determined
for each such step and summed up until value a f is attained. The total life
left is decided by the sum of total hours (cycles are converted to hours
from cycle duration and no. of cycles) obtained from calculations.
Residual Life thus computed is to be sub-divided into practical inspection

intervals. The next inspection is performed after the recommended time
duration especially concentrating on such locations where potential for
growth exists or a crack which existed previously but ground and weld
repaired during last outage. After the latest inspection data is obtained on
the locations of defects identified earlier, along with additional defects, if
any, new set of calculations on the basis outlined above with latest data as
inputs, is performed for residual life. Based on this revised estimate new
inspection intervals are recommended. This process is repeated for future
inspection.
5.0 TEST CONDUCTED: -
5.1 - Visual Examination: -
This is the most common and first inspection technique done by trained
personnel. The inspection is sometimes aided by magnifying glass. Records
consist of description of visual observations often aided by sketches,
photographs, vital measurements.
During the health assessment of Boiler components, components should be
first visually inspected to look for the damage, Disholoration, scaling, erosion,
corrosion, dust deposit etc. These factors give clue to the internal material
and stress status of the components.
5.2 - Dye-Penetrant Test.
This is perhaps one of the most widely used methods of non-destructive

testing, particularly for non-magnetic materials. Method is used for detection
of surface breaking cracks or Dishontinuities of non-porous solid material.

The method depends on the capillary action of a liquid, which enters into
cavities in the surface of an otherwise solid piece of material. It allows
detection of surface cracks, laminations, lap and porosity in the surface of all
kinds of material regardless of size, chemical composition or configuration.
5.3 - In-Situ Metallography:-
In-Situ Metallography is a NDE technique that is used on high temperature

components operating in creep range, such as Headers, tubes, Drum, Valves
etc. to determine possible creep damage. Due to the ability of this test being
performed “In-Situ”, it is a very important NDT technique to use for
component damage assessment and determination of remaining life. The
component to be evaluated is prepared for examination by grinding, polishing
and etching. For examination at higher magnification the microstructure of the
parent metal is recorded and examination in the laboratory on acetate replica
tape.
5.4 - Dimensional Measurement:-
The components liable for deformation / bulging due to wear creep namely
Headers & tubes etc. were thoroughly cleaned and dimensions measured to
observe the extent of deformation.
5.5 - Ultrasonic Thickness Measurement (UT-T):-
UT thickness measurements are made on tubes and headers etc. to know the
remaining thickness after erosion and corrosion.
5.6 – Fibroscopy examination

Fibroscopic inspection was conducted to know the internal surfaces condition
of different critical headers, tubes, etc. The locations are shown in sketch and
surface conditions are shown in photographs. The internal surface was
observed for pits, corrosion or cracks.
6.0 LABORATORY TEST ON TUBE SAMPLES
6.1 Tube samples from critical zones are removed for detailed examination
and analysis in laboratory. Tube samples cut on each boiler for
Examination at Laboratory
(a) Eco tube from low temperature zone
(b) Eco tube from high temperature zone
Requirements of scope of work as given in have been duly covered.
7.0 CALCULATIONS DONE TO ARRIVE AT REMNANT LIFE
7.1 The calculations were carried out as per IBR regulation

requirements. The following methodology has been considered in the
calculations
Remnant life has been worked out on the basis of

a) Reduction of thickness
b) Micro Structure degradation & Diffusional analysis of
microstructure.
c) Degradation because of oxide scale formation
d) LMP method to estimate Remaining life
Minimum measured thickness has been considered for calculation of
maximum, permissible working pressure.

7.2 Assessment of structural integrity of tubes has been assessed as
below.
For Max permissible working pressure for tubes as per IBR 338 Eqn.
87.
Formula:
WP = 2F (t-C) / (D-t + C)
WP = Design working pressure in kg/cm2
Ts = Minimum tensile strength at room temperature.
Et = Yield point strength at room temp.
Sr = Average stress at working temperature & working metal to produce
rupture in 1,00,000 hours and in no case more than 1.33 times the
lowest stress produced in 1,00,000 hours.
Sc = Average stress at working temperature of metal to produce elongation
of 1% creep in 1,00,000 hours.( Sc values are not available in
material standard and such material are known to have been used in
boilers)
F = Permissible stress at working temperature
F is minimum of following
Ts/2.7 or Sr/1.5 or Sc or Et/1.5 for temperature less than 454⁰c
Sr/1.5 or Sc whichever is lower for temperature above 454⁰c
t = Nominal wall thickness after negative thickness tolerance
adjustment.
C = 0.75 mm for WP upto and including 70kg/cm2.
= 0 for WP upto exceeding 70kg/cm2.
D = Outer Diameter of tube.
Minimum required thickness
Equation 87 is used for finding minimum thickness required to support the

design working pressure for permissible stress at working pressure.
Formula:
T min = [(WP) (D+C) + 2FC] / (2F+WP)
T min = minimum wall thickness required.
(b) Life assessment based on cavity classification / structural

degradation in the replica taken on the component for life fraction
expended ( texp/tr) as per Nuebauer & Wedel method. Ref graph &
table 2.4 (c)
Formula:
trem = (1/x – 1) x texp.
trem = Remaining life
texp = Expended operated life
texp/tr = Life fraction expended = x(based on microstructure
degradation level)
tr = Rupture life.
(c)Estimation of Remaining life by in situ oxide scale measurement:

 1 mils = 25.4 microns
 K = oxide scale growth constant
Formulae used for data validation:
1. T®(13.62+log to)=P
T® : temp. in Rankine
to : Operating hour in time interval i.e to1 , to2 , to3 ,---
P : Larson Miller Parameter obtained from oxide scale thickness in mills
Vs LMP Curve
2. WP(D-T)/2T=Hoop Stress
WP : working pressure in kg/cm²
D: Diameter in mm.
T: Thickness of tube in mm.
3. T® (20+log tr)= P (Larson Miller Parameter )
T®: temperature in rankine as obtained in S.No.1 for each time interval
i.e T1® , T2®, T3®,---
tr: : Rupture time in each time interval i.e tr1 , tr2 , tr3 ,----
P: Larson Miller Parameter obtained from LMP Vs Hoop stress curve
4. Total running hours till date / t r =Life fraction=X( expented life fraction in
each interval of time i.e X1 , X2 , X3 ,---
5. {(1-a) /a} *life expended =Remaining life
6. a = (X1 + X2 + X3+ ------+Xn )
a = Total life expended in period Xn.
(d) Estimation of remaining life by LMP method
(i) A typical methodology for estimation of remaining life using well
established Larsen Miller parameter (LMP) approach has been used as
below.
Formula:
LMP = T x 10-3 x [Log (tr) + 20]
T = Temperature in 0 Rankine = (0F +
460)
tr = Rupture life in hours.
LMP = Larsen miller parameter
Nominal stress (ksi) = (WP x D x 14.22) / (2t x1000)
(ksi - kilo pounds per sq. inch)
LMP can be obtained from nominal stress versus LMP creep curves of the
materials.
Values taken from nearest material composition.

Remaining life = tr - operating life

8.0 NDT PROCEDURES
Applicable codes and standard and Procedure followed for NDT
A PROCEDURE FOR VISUAL INSPECTION
1.0 Scope:
1 . 1 This procedure is applicable for Visual Inspection of

internal and external surfaces of equipments, pressure vessels and
piping.
2.0 Purpose:
2.1 Visual Inspect ion shall be performed to check the surface

condition and any deterioration during service.
3.0 Reference Documents:
3.1 ASME B & P V Code: Section: V, VIII

3.2 SNT-TC-1Aof ASNT
3.3 IBR Regulation 391, 391A,(a) (b), table 1 & 2
4.0 Inspection Aid:
4.1 Magnifying Glass 20X magnification shall be used for

minute observation on area selected as per surface condition.
5.0 Lighting:
5.1 Minimum light intensity at examination surface shall be 500

Lux.
6.0 Examination:
6.1 Examination shall be conducted thoroughly on all

areas.
Any abnormality observed shall be investigated and
reported.
6.2 In case of deep pitting/corrosion, area shall be
ground
smooth and thickness measurement shall be performed for
assessing the remaining thickness and acceptance. .

B. PROCEDURE FOR LIQUID PENETRANT TESTING
1.0 Scope:
1.1 This procedure is applicable for Liquid Penetrant

Examination of weld joints and heat affected area and
components.
2.0 Purpose:
2.1 Liquid Penetrant Examination shall be performed to detect

Discontinuities open to surface.
3.0 Technique:
3.1 Solvent removable visible dye technique shall be utilized.
4.0 Reference Documents:
4.1 ASME B&PV Code: Section: V, VIII

4.2 ASTM Standard: E-165 & E-1220
4.3 SNT-TC-1A of ASNT
4.4 IBR Regulation 391, 391A,(a) (b), table 1
5.0 Procedure Requirements:

5.1 Liquid penetrant testing shall be performed as per this
procedure. It describes various processes, information and
requirements for effective performance of the test. Only parameters
and materials described in this procedure shall be utilized. In case of
any change, a revised procedure shall be required.
6.0 Examination Coverage:
6.1 Weld Joints: Weld and minimum 25 mm area on both

sides of the weld from weld edge shall be tested.
7.0 PT Materials:
7.1 Following brand of Magnaflux make PT materials shall be used:
Penetrant : SKL-SP
Cleaner : SKC-1
Developer : SKD-S2
8.0 Control of Contaminants:
8.1 Certification of contaminant content for all liquid penetrant

materials used on nickel base alloys, austenitic stainless
steels and titanium shall be obtained.

8.2 These certificates shall include manufacturer's batch
number and test results in accordance with 8.3 & 8.4 below.
8.3 When examining nickel base alloys, Sulphur content shall

not exceed 1% of the residue by weight.
8.4 When examining Austenitic Stainless Steel or Titanium,
Chlorine and Fluorine content shall not exceed 1% by
weight.
9.0 Surface Preparation:
9.1 The surface to be tested shall be free from dust, grease,

scale or any other matter that could interfere with the
testing. Cleaning shall be conducted by buffing.
9.2 The test surface shall be free from irregularities that could
mask the indications due to Discontinuities.
9.3 After cleaning, test surface shall be wiped with lint free
cloth and cleaner,
9.4 Drying of the surfaces to be examined shall be
accomplished by normal evaporation.
10.0 Standard Temperatures:
10.1 The temperature of the penetrant and the surface of the

object to be tested shall be neither below 10°C nor above 52°C
throughout the examination period.
11.0 Examination:
11.1 Penetrant Application:
11.1.1 Penetrant shall be applied over examination surface by

brushing
11.2 Penetrant Time:
11.2.1 Penetrant shall be allowed to remain over test surface for at

least 10 minutes (dwell time)
11.3 Excess Penetrant Removal:
11.3.1 After dwell time, the excess penetrant shall be removed by

wiping with a lint free cloth. Repeating the operation until most traces
of penetrant have been removed. The remaining traces shall be
removed by lightly wiping the surface with lint free cloth moistened
with solvent. To minimize removal of penetrant from Discontinuities,
care shall be taken to avoid the excess use of solvent. Flushing the
surface with solvent, following the application of penetrant
and prior to developing, is prohibited.
11.4 Drying After Excess Penetrant Removal:

11.4.1 The surface shall be dried by normal evaporation.
11.5 Developing:
11.5.1 Developer shall be applied as soon as possible after penetrant

removed and surface has dried but shall not exceed five minutes from
time of penetrant removal.
11.6 Developer Application:
11.6.1 Non-aqueous developer shall be applied

to dry surface.
11.6.2 A thin and uniform coating of Developer

shall be applied over examination surface by spraying.
12.0 Inspection:
12.1 After application of developer, the test surface

shall be
closely observed for appearance of any indication.
12.2 Inspection shall be performed under white light.

The
minimum light intensity at the test surface shall be 1000 lux.
12.3 Mirror/Magnifying Len may be used to

facilitate the
inspection.
12.4 Developing time for final interpretation begins
immediately
as soon as developer coating is dry.
12.5 The test surface shall be kept under
observation for 10
minutes
13.0 Interpretation:
13.1 Final interpretation shall be made after 10 to 60 minutes.
14.0 Evaluation:
14.1 The size of the indication is the basis for
acceptance
evaluation. Only indications, which have any dimension
greater than 1.6 mm, shall be considered as relevant.
14.2 A linear indication is one having a length greater
than 3
times the width.
14.3 A rounded indication is one of circular or
elliptical shape
with a length equal to or less than three times its width.
15.0 Acceptance Criteria:

(a) Imperfections producing the indications shall be
evaluated as per design code of vessel.

C PROCEDURE FOR ULTRASONIC THICKNESS GAUGING:
1.0 Scope:
1 . 1 This procedure is applicable for Ultrasonic Thickness Gauging

of vessels and piping.
2.0 Purpose:
2.1 Ultrasonic Thickness Gauging shall be performed for assessing

remaining thickness.
3.0 Technique:
3.1 Digital Read out Equipment operating on Pulse Echo Technique

shall be utilized.
Reference Documents:
4.1 ASME B & PV Code: Section: V, VIII

4.2 SNT-TC-1A of ASNT
4.3 ASTM Standard SA 797
Surface Preparation:
The location for thickness measurement shall be free from dust, scale or
any other matter that could interfere with the effective coupling and the
thickness reading.The thickness measurement shall be performed at
ambient surface temperature.
6.0 Calibration:
The Ultrasonic Thickness Meter shall be calibrated using the block of

thickness within ±10% of the job thickness and having acoustic velocity
similar to the test object.
7.0 THICKNESS GAUGING LOCATIONS:
Thickness locations shall be shown in sketch or described in thickness report.

D Procedure for In-Situ Metallography / Replication
1.0 SCOPE:
1.1.1 This procedure is applicable for in-situ metallography of Tubes, piping
& weld surface.
2.0 PURPOSE:
2.1.1 Metallography is performed to obtain Metallurgical structure of material
to study the degradation level.
3.0 PRINCIPLE:
3.1.1 Sampled location is cleaned, grind and polished to the extent that
micro structure is visible. Quality of polish and microstructure is
observed through portable microscope. Image is stored as soft copy
and transferred to PC for study and interpretation.
4.0 CAPABILITIES & LIMITATION:

4.1.1 This provides information about internal condition of material.
Degradation at grain level can be viewed to study the aging effect of
component in service.
5.0 REFERENCE DOCUMENTS:

5.2 ASTM Standard for metallography.
6.0 PROCEDURE:
6.1 Select the locations for metallography
6.2 Perform preliminary cleaning for removal of scale, rust oil etc.
6.3 Grind the surface to make it smooth, if pitting is present.
6.4 Perform buffing of the spot using different grades of buffing wheels.
6.5 Perform polishing with polish paper and polishing liquid.
6.6 Clean and wash the surface.
6.7 Chemical etching after cleaning the surface.
6.8 Inspect the surface for grain structure and record the image.
6.9 Take Replication on gold plated & / or Replication strip.
6.10 Replica will be studied through an optical microstructure in the
laboratory.
7.0 STUDY:
7.1 Study the microstructure recorded and the image with reference
structures for study of degradation.

REMAINING LIFE OF BOILER PRESSURE PARTS
Remaining Life of Boiler Pressure Parts has been calculated by considering

the following
1. Nuebauer and Wedel method of interpretation of microstructural

damage and prediction of remnant life based on Microstructure
degradation levels as furnished in the report.
2. Reduction of thickness.
3. Oxide thickness inspection
4. Destructive test results.
 The expended life of each of these categories has been evaluated
as per the criteria mentioned on page 14, 15 and 16.
Expended Life Fraction as furnished in the next sheet has been worked out
as the least of the findings of microstructure from metallographic test finding
as per Neubauer and Wedel classification for cavitations and crack growth,
reduction in thickness, in situ oxide scale thickness measurement and
destructive test results of tube samples.

Evaluating Remaining Life of Boiler Pressure Parts
The boiler is in operation after commissioning in 1993 for around 24 years

and actual running hours as per KSFL records =100000 hours
Sr. No. Component Expended Minimum Remaining

Life fraction Life in Hours
(X)
1. DRUM 0.46 117391
2. De Super heater 0.46 117391
3. Economiser tube 0.46 117391
4. SH header tube 0.46 117391
5. Main Steam line 0.46 117391
6. Economiser header 0.46 117391
7. Super Heater Header 0.46 117391
8. Feed water line 0.46 117391

Recommendation of Run Repair Replacement and Conclusion
Based on the analysis and the studies presented in various chapters of the
forgoing text and out of the NDTs / DTs carried out on the components for
Boiler & Auxiliaries of HRSG # 1 (Regn. No. UP- 5318) of Kribhco Shyam
Fertilizers. The following are component wise recommendations.
Sr. Component Recommenda Six Year Action Plan

No. tion
1st 2nd 3rd 4th 5th 6th year
year year year year year
1. DRUM Run Nil Nil Nil Nil Nil next RLA will
be done
2. De Super Run Nil Nil Nil Nil Nil next RLA will
heater be done
3. Economiser Run Nil Nil Nil Nil Nil next RLA will
tube be done
4. SH header Run Nil Nil Nil Nil Nil next RLA will
tube be done
5. Main Steam Run Nil Nil Nil Nil Nil next RLA will
line be done
6. Economiser Run Nil Nil Nil Nil Nil next RLA will
header be done
7. Super Heater Run Nil Nil Nil Nil Nil next RLA will
Header be done
8 Feed water line Run Nil Nil Nil Nil Nil next RLA will
be done
Definitions of terminology used in the report are as follow
Run : Fit for reuse

Repair : Repair damage part by welding grinding and other suitable
technique to make the equipment fit for continuous operation.
Replacement : Change the equipment by new equipment

CONCLUSION
Based on the results of tests carried out during the course of RLA study, It
is concluded that the HRSG # 1 (Regn. No. UP- 5318) is found to be
suitable for continuous operation for another ten to twelve years provided
all the specific recommendations as brought out in this report are
implemented. It is also concluded that the Boiler components are suitable
for continuous operation with no alteration in the licensed working
pressure provided the unit is operated as per design / rated operating
regime and is maintained as per OEM recommendations. Even though the
residual life is coming out to be more than ten years, still it is
recommended that RLA study be carried out after five years. This is to
assess the effect of any abnormal stresses arising out of any mal-
functioning of the boiler controls resulting in operation of unit at higher
parameters.

SUMMARY OF TEST REPORTOF DRUM
Sl. Test Observations

No.
1 Visual  Drum visually inspected both inside & outside.
Inspection  Thin layer of corrosion observed on outer surface
and inner surface of HP drum.
 Pitting observed at the inner surface of weld &
parent metal. Pitting depth found up to 1.0 mm.
2 DPT  Dye penetrant test carried out on circumferential,
long seam weld, tapping point joints & stub joints.
No significant defect observed.
3 UT  Circumferential & long seam weld joints were
checked by ultrasonic method and no remarkable
4 In-situ  As per Wedel-Neubauer classification the
Metallography component is in between level I & level II.
& Hardness
5 Internal  Drum deposit analysis indicates chemical
deposit composition within limit.
analysis
6 ID &  ID & Thickness measured at different locations and
Thickness no major deviation recorded.
Dimensional measurement:
BOILAR DRUM (DISHEND)

THICK(LHS) THICK(RHS)
1 61.1 ,59.5 62.0
2 60.3 ,59.2 61.2
3 61.0 60.3
4 60.9 60.0
BOILAR DRUM (SHELL)

THICK THICK ID
1 77.0 5 77.9 1750.6
2 78.5 6 78.4 1750.0
3 77.5 7 76.9 1750.2
4 74.3 8 78.1 1750.9
ECO O/L TO DRUM LINK PIPE-1

THICK OD
1 13.9 170.1
2 14.1 170.2
3 13.5 170.0
4 14.0 170.1
ECO O/L TO DRUM LINK PIPE-2

THICK OD
1 14.7 170.1
2 13.7 170.1
3 14.0 170.2
4 14.2 170.0
HARDNESS TEST REPORT

STEAM DRUM:
WELD M: 150; 155; 145
HAZ: 140; 142; 143
PM: 112; 110; 114
Recommendation:
Based on visual inspection, Dye Penetrant test, Ultrasonic test, In-situ

Metallography, Deposit analysis, Hardness measurement and
dimensional measurement, Drum was found in satisfactory condition.
drum will work efficiently for more than 10 years. However the re-
inspection of the component is recommended as per IBR 391 A.
Residual Life:
If further operating condition continues as in the past, it is expected that the

Drum will remain fit for further service for more than 10 years as it is observed
during testing that there is less variation in thickness & dimension
measurement & microstructure is nearly matching damage class ‘1’ .
.

TEST REPORT
BOILER & AUXILIARIES
Visual Inspection Report

Equipment Magnifying Glass Customer KSFL,Shahjahanpur
Used
Report No. VI-01 Date of 05/7/17 TO 08/7/17
Inspection
SL Compone Observation Recommendation
No. nt
1 Drum Drum visually inspected externally Based on the observation
& internally. thin layer of corrosion and the assessment after
observed on the outer surface of analysis , the drum is fit
the drum. No other significant for continued operation
defect/ discontinuity was Since the pitting depth is
observed. within the permissible
limit hence only proper
insulation of outer
surface of drum is
sufficient.

Magnetic Particle Test Report

Particular of test Wet fluorescent Magnetic Particle Testing
Surface condition Free from loose scale, dust, paint, oil & grease. Surface
was clean & dry.
Equipment used Magnaflux (Yoke) Wet/Dry Method
Lifting capacity AC -6kg and HWDC – 16kg with yoke spacing 100mm
Type of magnetic particle Wet – Fluorescent
Method of magnetising Continuous Yoke
Magnetising current AC
Direction of field Longitudinal
Sensitivity checks PIE Field Indicator
Demagnetization Not done
Specification ASTM E709-1995
Test Result:
Sl. Name of components Qty. Finding/ Observation Remark
No. tested
A Steam drum
1 Longitudinal weld seam 1 No recordable Acceptable
discontinuity
observed
2 Circumferential weld seam 2 No recordable Acceptable
discontinuity
observed
Result Accepted All Defects Noticed Nil

Ultrasonic Testing Report (UT)

Equipmen UT Machine Customer KSFL,Shahjahanpur
t Used
Report UT-01 Date of 05/7/17 TO 08/7/17
No. Inspection
Equipment and Ultrasonic flaw detector models DG Scan 322 make Parikh
Material Used Industry, normal and angle beam probes, calibration block
V1 & V2, grease oil mix.
Equipment Equipment Surface As Cleaned
Calibration calibration by V1 Conditio
& V2 block n
Tested / Accepted As per ASME sec V
Test Parameter
Probe Size Freq Range of Machine Setting
CRT
Technique Dia (mm) /angle MHz Mm Puls Amplitud Suppression
e db e%
Straight Beam ø 10/ 00 2 0-100 32 80 % Nil
FSH
Angle Beam 8X9 mm/450 2 0-250 36 80 % Nil
FSH
Observation
Component Drum
S. NO Component Quantity Interpretation Remarks
01 Circumferenti 02 Nos. No remarkable Acceptable
al Joints indication
observed.
02 Longitudinal 01 Nos. No remarkable Acceptable
Joints indication
observed.
Result Accepted All Defects Nil
Noticed

Dye Penetration Test Report (DPT)

Equipment Used DPT Kit & Customer KSFL,Shahjahanpur
Magnifying
Glass
Report No. DPT-1 Date of Inspection 05/7/17 TO 08/7/17
Tested / Accepted As Per ASME Sec V
Test Material Non-Fluorescent Red Dye Penetrant
Technique Solvent Removable Visible Dye Penetrant
Method of Pre-cleaning Buffing followed by solvent cleaning using aerosol
spray
Penetrant Used Visible Red Dye Penetrant
Make Orion
Dwelling Time 10-15 minutes
Cleaner Used
Brand Name Orion
Developer Used
Brand Name Orion
Developing Time 05 minutes
Method of Inspection Using magnifying glass
Observation
Component Drum
S.NO. Component Quantit Interpretation Remarks
y
1 Circumferential joints 02 Nos. No surface defect Acceptable
2 Longitudinal Joints 02 Nos. No surface defect Acceptable
3 Stub joints Riser Tube & All No surface defect Acceptable
link pipe which are
assessable
Resul Accepted All Defects Noticed Nil
t
In Situ Metallography Evaluation Report ( RPL)

Equipment Replica KIT Customer KSFL,Shahjahanpur
Used
Report No. RPL-01 Date of Inspection 05/7/17 TO 08/7/17
Material used Cleaner, Polishing machine, Etchant, Metal foil, Microscope
Component Drum
Location RHS – Parent Metal
200X
Observation Microstructure show predominent structure of pearlite & farrite.
No microstructural degradation is observed.
Life Fraction As per Wedel–Neubauer classification the component is in
between level I & level II, i.e expended life fraction is 0.38.
Recommendation This microstructure does not show any metal degradation. As per
general internationally accepted classification of creep cavitation,
this microstructure matches nearly damage class ‘1’ which
corresponds to no creep cavitation.


Equipment Magnifying Customer KSFL,Shahjahanpur
Used Glass
Report No. RPL-02 Date of Inspection 05/7/17 TO 08/7/17
Component Drum
Location RHS – Parent Metal
200X
Observation Microstructure show predominent structure of pearlite & farrite.
general internationally accepted classification of creep cavitation,
this microstructure matches nearly damage class ‘1’ which
corresponds to no creep cavitation.

SUMMARY OF TEST REPORT OF MAIN STEAM LINE

No.
1 Visual  Main Steam Line visually inspected outside.
and inner surface of Main Steam Line.
2 DPT  Dye penetrant test carried out on circumferential,
tapping point joints & stub joints. No significant
defect observed.
3 UT  Circumferential & long seam weld joints were
checked by ultrasonic method and no remarkable
& Hardness
6 OD &  OD & Thickness measured at different locations and
MAIN STEEM LINE

THICK THICK(BEND) OD
1 25.2 27.7 220.0
2 25.7 28.2 219.8
3 25.4 27.6 219.9
4 24.7 27.9 220.1
PM : 142,138
WM: 157,162
Recommendation:

Metallography, Hardness measurement and dimensional
measurement, Main Steam Line was found in satisfactory
condition.Main Steam Line will work efficiently for more than 10 years.
However the re-inspection of the component is recommended as per
IBR 391 A.

Residual Life:

Main Steam Line will remain fit for further service for more than 10 years as it
is observed during testing that there is less variation in thickness & dimension
.
TEST REPORT

Equipment Magnifying Glass Customer KSFL,SHAHJAHANPUR
Used
Inspection
No. nt
1 Main Main Steam Line visually Based on the observation
Steam inspected In visual inspection and the assessment after

Main Steam Line .Thin layer of analysis , the Main
Line
corrosion found. No other Steam Line is fit for
significant defect/ discontinuity continued operation
was observed.


Equipment UT Machine Customer KSFL,Shahjahanpur
Used
Report No. UT-04 Date of
Inspection
Equipment and Ultrasonic flaw detector models DG Scan 322 make EEC,
Material Used normal and angle beam probes, calibration block V1 & V2,
grease oil mix.
Equipment Equipment calibration by V1 & V2 Surface As
Calibration block Condition Cleane
d
Tested / As per ASME sec V
Accepted
Test Parameter
CRT
Technique Dia (mm) MHz mm Pulse Amplitude Suppres
/angle db % sion
Straight Beam ø 10/ 00 2 0-100 32 80 % FSH Nil
Angle Beam 8X9 mm/450 2 0-250 36 80 % FSH Nil
Observation
Component MAIN STEAM LINE
S. NO Component Quantity Interpretation Re
m
ar
ks
01 Circumferential 02 Nos. No remarkable indication Ac
Joints observed. ce
pta
ble
04 Stub joint of safety 02 Nos. No remarkable indication Ac
valve observed. ce
pta
ble
t


Equipment Used DPT kit Customer
Report No. DPT-04 Date of Inspection 04/07/17 TO 0707/17

spray
Make Orion
Cleaner Used
Brand Name Orion
Developer Used
Brand Name Orion
Observation
Component MAIN STEAM LINE
y
t


Used Glass
Report No. RPL-06 Date of Inspection 05/07/2017 to 07/07/2017
Component Main steam line WM
200X
Observation Microstructure shows columnar ferrite & pearlite/ bainite
structure. No microstructural degradation is observed.
Recommendation This microstructure does not show any metal degradation. As
per general internationally accepted classification of creep
cavitation, this microstructure matches nearly damage class ‘1’
which corresponds to no creep cavitation.


Used Glass
Component Main steam line PM
200X

SUMMARY OF TEST REPORTOF EVAPORATOR
HEADER(TOP & BOTTOM)

No.
1. Visual  HP Evaporator O/L Header visually inspected
Inspection outside.
2. DPT  Dye penetrant test carried out on circumferential
seam weld, tapping point joints & stub joints. No
significant defect observed.
3. OD &  OD & Thickness measured at different locations and
4. Hardness  Hardness carried out at header.
EVAPORATOR HEADER
THICK OD
1 34.6 N.A
2 35.0 N.A
3 34.0 N.A
4 35.9 N.A
Hardness: 132,137
Recommendation:
Based on visual inspection, Dye Penetrant test, and dimensional

measurement, Evaporator Header was found in satisfactory
condition.Evaporator Header will work efficiently for more than 10
years. However the re-inspection of the component is recommended
as per IBR 391 A.
Residual Life:

Evaporator Header will remain fit for further service for more than 10 years as
it is observed during testing that there is less variation in thickness &
dimension measurement & microstructure is nearly matching damage class
‘1’ .
.

TEST REPORT

Equipment Magnifying Glass Customer KSFL,Shahjahanpur
Used
Report No. VI-06 Date of 05/07/17 to 07/07/17
Inspection
No. nt
1 Evaporator Evaporator Header visually Based on the observation
Header inspected In visual inspection HP and the assessment after
Evaporator Header . No other analysis , the Evaporator
significant defect/ discontinuity Header is fit for continued
was observed. operation


Equipment Used DPT Kit & Customer KSFL,Shahjahanpur
Magnifying
Glass
Report No. DPT-06 Date of Inspection 05/07/17 to 07/07/17
spray
Make Orion
Cleaner Used
Brand Name Orion
Developer Used
Brand Name Orion
Observation
Component HP Evaporator HEADER
y
1 Stub joints All No surface defect Acceptable
t


Equipment UT Machine Customer KSFL,Shahjahanpur
Used
Report No. UT-01 Date of 05/07/17 to 07/07/17
Inspection
Equipment and Ultrasonic flaw detector models dg Scan 322 make Parikh
Material Used Industry, normal and angle beam probes, calibration block V1 &
V2, grease oil mix.
Equipment Equipment calibration Surface As Cleaned
Calibration by V1 & V2 block Condition
Tested / Accepted As per ASME sec V
Test Parameter
CRT
Technique Dia (mm) MHz mm Pulse Amplitude Suppres
/angle db % sion
Observation
Component HP EVAPORATOR HEADER
S. NO Component Quantity Interpretation Re
m
ar
ks
01 Circumferential all No remarkable indication Ac
Joints observed. ce
pta
ble
t

SUMMARY OF TEST REPORTOF EVAPORATOR TUBE

No.
1 Visual  HP Evaporator tube visually inspected outside.
Inspection
Recommendation:
Based on visual inspection and dimensional measurement, vaporator

tubes was found in satisfactory condition. HP evaporator tubes will
work efficiently for more than 10 years. However the re-inspection of
the component is recommended as per IBR 391 A.
Residual Life:

evaporator tubes will remain fit for further service for more than 10 years as it
.

TEST REPORT

Equipment Magnifying Glass Customer KSFL
Used
Report No. VI-07 Date of 05/07/17 to 07/07/17
Inspection
No. nt
1 Evaporator Evaporator Tube visually Based on the observation
tubes inspected In visual inspection and the assessment after
Evaporator Tube . No other analysis , the Evaporator
significant defect/ discontinuity Tube is fit for continued
was observed. operation

EVAPORATER-1 COILS
SR NO. THICK OD
1. 4.9 51.1
2. 5.0 51.2
3. 4.8 51.0
4. 4.9 51.0
5. 4.8 51.3
6. 4.8 51.2
7. 4.9 51.1
8. 4.8 51.2
9. 5.0 51.3
10. 5.0 51.1
11. 5.0 51.2
12. 4.9 51.1
13. 5.2 51.0
14. 4.8 51.2
15. 4.9 51.1
16. 5.0 51.0
17. 5.0 51.3
18. 4.7 51.2
19. 4.9 51.1
20. 5.1 51.3
21. 5.0 51.2
22. 4.8 51.1
23. 4.7 51.3
24. 4.9 51.0
25. 4.9 51.0
26. 5.1 51.2
27. 5.0 51.1
28. 5.0 51.1
29. 4.9 51.2
30. 4.8 51.0

EVAPORATER-2 COILS
SR NO. THICK OD
1. 4.6 51.0
2. 4.8 51.1
3. 4.7 51.2
4. 4.9 51.1
5. 4.9 51.1
6. 4.7 51.0
7. 4.6 51.2
8. 4.7 51.0
9. 4.9 51.1
10. 5.0 51.2
11. 4.7 51.1
12. 4.9 51.1
13. 4.8 51.2
14. 4.6 51.1
15. 4.9 51.1
16. 5.1 51.2
17. 5.0 51.1
18. 5.0 51.2
19. 4.7 51.1
20. 4.8 51.1
21. 5.0 51.0
22. 4.9 51.0
23. 4.9 51.2
24. 4.8 51.1
25. 5.0 51.2
26. 4.9 51.1
27. 5.0 51.0
28. 5.2 51.1
29. 4.9 51.2
30. 4.8 51.0

SUMMARY OF TEST REPORTOF DE SUPER HEATER

No.
1 Visual  De super heater visually inspected outside.
and inner surface of De super heater.
2 DPT  Dye penetrant test carried out on circumferential
3 UT  Circumferential seam weld joints were checked by
ultrasonic method and no remarkable indication
observed.
& Hardness
De Super heater Header

THICK OD
1 24.6 275.6
2 24.9 275.4
3 24.7 275.5
4 23.9 275.7
PM: 143,148,132
WM: 157,164,162
Recommendation:

Metallography, Hardness measurement and dimensional
measurement, De super heater was found in satisfactory condition.De
super heater will work efficiently for more than 10 years. However the
re-inspection of the component is recommended as per IBR 391 A.
Residual Life:

De super heater will remain fit for further service for more than 10 years as it
.
TEST REPORT

Equipment Magnifying Glass Customer KSFL,SHAHJAHANPUR
Used
Inspection
No. nt
1 De Super De super heater visually inspected Based on the observation
Heater In visual inspection De super and the assessment after
heater .Thin layer of corrosion analysis , the De super
found. No other significant defect/ heater is fit for continued
discontinuity was observed. operation


Equipment UT Machine Cust KSFL Shahjahanpur
Used
Report No. UT-04 Date of 05/07/17
Inspection
Equipment and Ultrasonic flaw detector models P X 10 make Parikh Industry, normal and
Material Used angle beam probes, calibration block V1 & V2, grease oil mix.
Tested / As per ASME sec V Report No. F25/RLA/BRPL/BLR3/08
Accepted
Test Parameter
CRT
Technique Dia (mm) MHz mm Pulse Amplitude Suppression
/angle db %
Observation
Component DE SUPER HEATER
01 Circumferential 02 Nos. No remarkable indication Acceptable
Joints observed.
04 Stub joint of safety 02 Nos. No remarkable indication Acceptable
valve observed.
t

Equipment Used DPT kit Customer Ksfl,shahjahanpur
Report No. DPT-04 Date of Inspection 06/07/17

spray
Make Orion
Cleaner Used
Brand Name Orion
Developer Used
Brand Name Orion
Observation
Component DE SUPER HEATER
y
t


Used Glass
Component De super heater WM
200X


Used Glass
Component De super heaterPM
200X

SUMMARY OF TEST REPORT OF FEED WATER LINE
Sl. No. Test Observations

1 Visual Inspection  Feed Water line visually inspected outside.
 Thin layer of corrosion observed on outer surface
2 DPT  Dye penetrant test carried out on circumferential, long
3 UT  Circumferential & long seam weld joints were checked by
ultrasonic method and no remarkable indication observed.
6 OD & Thickness  OD & Thickness measured at different locations and no
major deviation recorded.
FEED WATAR LINE

THICK OD
1 14.9 170.3
2 15.5 170.2
3 14.9 170.0
4 15.3 170.1
Recommendation:
Based on visual inspection, Dye Penetrant test, Ultrasonic test,and dimensional

measurement, Feed Water line was found in satisfactory condition. Feed Water line
will work efficiently for more than 6 years However the re-inspection of the
component is recommended as per IBR 391- A.
Residual Life:
If further operating condition continues as in the past, it is expected that the Feed
Water line will remain fit for further service for more than 6 years as it is observed
during testing that there is less variation in thickness & dimension measurement &
microstructure is nearly matching damage class ‘1’ .
.

TEST REPORT

Equipment Used Magnifying Glass Customer KSFL SHAHJAHANPUR
Report No. VI-01 Date of Inspection 05/07/2017 to 07/07/2017

SL Component Observation Recommendation
No.
1 Feed Water Feed Water line visually inspected Based on the observation
line externally . In visual inspection minor and the assessment after
pitting observed. No other significant analysis, the Feed Water line
defect/ discontinuity was observed. is fit for continued operation


Equipment Ultrasonic flaw detector models P X 10 make Parikh Industry, normal and
and Material angle beam probes, calibration block V1 & V2, grease oil mix.
Used
Tested / As per ASME sec V Report No.
Accepted
Test Parameter
CRT
Techniq Dia (mm) MHz mm Pulse Amplitude Suppression
ue /angle db %
Straight ø 10/ 00 2 0-100 32 80 % FSH Nil
Beam
Angle 8X9 mm/450 2 0-250 36 80 % FSH Nil
Beam
Observation
Component Feed Water line
01 Circumferential 02 Nos. No remarkable indication Acceptable
Joints observed.


Method of Pre-cleaning Buffing followed by solvent cleaning using aerosol spray
Make Orion
Cleaner Used
Brand Name Orion
Developer Used
Brand Name Orion
Observation
Component Feed Water line
y


Surface condition Free from loose scale, dust, paint, oil & grease. Surface was
clean & dry.
Test Result:
No. tested
A Feed Water line
2 Circumferential weld seam 2 No recordable Acceptable
discontinuity observed


Equipment MICROSCOPE Customer KSFL SHAHJAHANPUR
Used
Component FEED WATER LINE
Location Weld Metal
200X
Observation Microstructure shows dendrite form of ferrite & pearlite structure.
Life Fraction As per Wedel–Neubauer classification the component is in between
level I & level II, i.e expended life fraction is 0.46 to 0.48.
general internationally accepted classification of creep cavitation, this
microstructure matches nearly damage class ‘1’ which corresponds to
no creep cavitation.


Equipment Magnifying Glass Customer KSFL SHAHJAHANPUR
Used
Component Feed Water Line
Location Parent Metal
200X
Observation Microstructure shows ferrite & pearlite structure. No microstructural
degradation is observed.
Life Fraction As per Wedel–Neubauer classification the component is in between
level I & level II, i.e expended life fraction is 0.46 to 0.48.
general internationally accepted classification of creep cavitation, this
microstructure matches nearly damage class ‘1’ which corresponds to
no creep cavitation.

SUMMARY OF TEST REPORT OF DOWN COMER , RISER TUBE , SATURATED TUBE
Sl. No. Test Observations

1 Visual Inspection  Down Comer , Riser Tube , Saturated Tube visually
inspected outside.
 Thin layer of corrosion observed on outer surface
2 DPT  Dye penetrant test carried out on stub joints. No
6 OD & Thickness  OD & Thickness measured at different locations and no
major deviation recorded.
DOWN COMER-1
THICK OD
1 24.7 275.0
2 24.5 275.0
3 25.3 275.3
4 24.9 275.1
DOWN COMAR-2
THICK OD
1 25.6 275.1
2 24.3 275.0
3 24.6 275.2
4 25.0 275.0
RISER TUBE
SR NO. THICK OD
1. 14.6 170.0
2. 14.3 170.2
3. 13.6 170.1
4. 13.9 170.1
5. 14.0 170.3
6. 14.3 170.0
7. 13.4 170.0
8. 14.5 170.1
9. 13.3 170.1
10. 13.7 170.0
11. 14.1 170.2
12. 13.9 170.1
13. 13.7 170.0

SATURATED TUBE
SR NO. THICK OD
1 9.7 100.3
2 10.0 100.2
3 9.6 100.0
4 9.9 100.1
Recommendation:
Based on visual inspection, Dye Penetrant test, ,and dimensional measurement

Down Comer , Riser Tube , Saturated Tube was found in satisfactory condition.
Feed Water line will work efficiently for more than 6 years However the re-
inspection of the component is recommended as per IBR 391- A.
Residual Life:
If further operating condition continues as in the past, it is expected that the Down
Comer , Riser Tube , Saturated Tube will remain fit for further service for more than
6 years as it is observed during testing that there is less variation in thickness &
dimension measurement & microstructure is nearly matching damage class ‘1’ .
.

TEST REPORT

Equipment Used Magnifying Glass Customer KSFL SHAHJAHANPUR

SL Component Observation Recommendation
No.
1 Down Feed Water line visually inspected Based on the observation
Comer , externally No other significant defect/ and the assessment after
Riser Tube , discontinuity was observed. analysis, the Down Comer ,
Saturated Riser Tube , Saturated Tube
Tube is fit for continued operation


Method of Pre-cleaning Buffing followed by solvent cleaning using aerosol spray
Make Orion
Cleaner Used
Brand Name Orion
Developer Used
Brand Name Orion
Observation
Component Down Comer , Riser Tube , Saturated Tube
y
1 Stub l joints ALL No surface defect Acceptable

ENERGO ENGINEERING PROJECTS LIMITEDKRIBHCO SHYAM FERTILIZERS
ECONOMISER HEADERS (INLET & OUTLET)

No.
1. Visual  ECONOMISER headers (inlet & outlet) were visually
Examination inspected and found in satisfactory condition.
2. DPT  Dye penetrant was carried on circumferential weld
joints, tube stub joints, attachment weld joints etc. No
significant surface defect observed.
3. Dimensional  Dimensional measurement carried out. Details
measurement measurements have been furnished separately in this
chapter.
Recommendation: Based on visual inspection, Dye Penetrant test,

dimensional measurement, the components were found in satisfactory
condition & suitable for further operation. However, re-inspection of
component is recommended afterr 6 year of operation to monitor the trend of
service induced damage and assess its fitness for further service as per IBR
1950 u/s. 391 A.

VISUAL INSPECTION REPORT
COMPONENT ECONOMISER HEADERS (I/L & TEST: VISUAL

O/L) INSPECTION
EQUIPMENT AND MATERIAL USED

Magnifying Glass
Flash Light
OBSERVATION
Sl. No. Component Interpretation Remarks
01 ECONOMISER ECONOMISER headers (I/L & O/L) Acceptabl

headers (I/L & e
were visually inspected. No significant
O/L)
abnormality could be observed.
Result: Acceptable

MAGNETIC PARTICLE EXAMINATION
COMPONENT: ECONOMISER TEST: MAGNETIC PARTICLE

HEADERS (I/L & O/L) EXAMINATION
Particular of Test: Wet fluorescent magnetic particle

test
Surface Condition: Free from loose scale, dust, paint, oil
& grease. Surface was clean & dry
Lifting Capacity: AC-5Kg & HWDC-27Kg with yoke
spacing 100mm
Type of Magnetic Particle: Wet fluorescent
Method of Magnetizing: Continuous Yoke
Direction of Field Longitudinal
Sensitivity Check Pie field Indicator
OBSERVATION
Sl.
Area of examination Interpretation Remarks
No.
01 No surface or sub surface defect Acceptable

Circumferential welds
observed.
RESULT : Acceptable

DYE PENETRANT EXAMINATION
COMPONENT: ECONOMISER HEADERS TEST: DYE PENETRANT

(I/L & O/L) EXAMINATION

1) Penetrant, Developer, Cleaner
2) Cleaning cloth
3) Magnifying glass
4) Inspection torch(light)
Dwell Time : 10-15 min Surface Condition : As cleaned

Development Time : 7 min Tested/Accepted : As per ASME sec V
Temp. Of component : 250-300
Approx.
OBSERVATION
Sl.
No.
Circumferential welds, No significant surface defect

01 Acceptable
stub joints, attachment observed.
welds etc.
RESULT : Acceptable

ULTRASONIC FLAW DETECTION
COMPONENT: ECONOMISER TEST: ULTRASONIC FLAW

HEADERS (I/L & O/L) DETECTION

1) Ultrasonic Flaw Detector
2) Normal and Angle beam probe
3) Calibration block V1 & V2
4) Grease, Oil/ Mix
EQUIPMENT CLIBRATION Surface condition: As cleaned
Equipment calibrated by V1 & V2 Method : Direct Contact
Block
PROBE SIZE FREQ. Range of Machine Settings
CRT
TECH. Dia MHz (mm) db Amp. Suppression
Angle 8X9 2.5/4 0 - 300 48 80% Nil

450 mm/ Ф
10 mm
SCANNING LEVEL : + 6 dB RECORDING LEVEL : 50

% FSH & ABOVE
OBSERVATION
Sl.
Area of Examination Interpretation Remarks
No.
Circumferential weld No recordable indication Acceptable

01
joints observed.
RESULT : Acceptable

ECONOMISER-2 COILS
SR NO. THICK OD
1. 4.9 51.1
2. 5.1 51.2
3. 5.0 51.1
4. 5.2 51.0
5. 4.9 51.0
6. 4.9 51.0
7. 5.0 51.0
8. 5.1 51.2
9. 4.9 51.1
10. 4.9 51.0
11. 4.7 51.0
12. 5.2 51.1
13. 5.0 51.1
14. 5.0 51.1
15. 4.8 51.0
16. 4.8 51.2
17. 5.0 51.1
18. 4.9 51.1
19. 4.8 51.0
20. 4.8 51.0
21. 4.7 51.2
22. 4.9 51.1
23. 5.0 51.2
24. 5.2 51.1
25. 5.0 51.1
26. 4.9 51.0
27. 4.8 51.2
28. 4.7 51.0
29. 4.9 51.2
30. 4.9 51.1
ECONOMISER-1 COILS
SR NO. THICK OD
1. 4.9 51.0
2. 4.8 51.1
3. 5.0 51.2
4. 5.2 51.1
5. 5.0 51.1
6. 4.9 51.2
7. 4.8 51.1
8. 4.8 51.1
9. 4.9 51.0
10. 4.9 51.2
11. 4.8 51.1
12. 4.9 51.1
13. 5.0 51.2
14. 5.1 51.0
15. 5.0 51.0
16. 5.3 51.1
17. 4.9 51.2
18. 4.7 51.0
19. 4.6 51.1
20. 5.0 51.0
21. 4.9 51.0
22. 4.7 51.2
23. 4.8 51.0
24. 4.9 51.2
25. 4.9 51.1
26. 4.7 51.2
27. 4.7 51.2
28. 4.9 51.0
29. 5.0 51.1
30. 5.0 51.2

ECONOMISER-2 G.T SIDE COILS

SR NO. THICK OD
1. 4.8 51.3
2. 4.7 51.2
3. 4.9 51.1
4. 4.9 51.3
5. 4.8 51.2
6. 4.7 51.1
7. 5.0 51.0
8. 4.9 51.2
9. 5.1 51.1
10. 4.7 51.3
11. 4.7 51.0
12. 5.0 51.0
13. 5.1 51.2
14. 4.8 51.1
15. 4.8 51.1
16. 4.9 51.0
17. 4.7 51.2
18. 5.0 51.1
19. 4.8 51.1
20. 4.7 51.2
21. 5.0 51.1
22. 4.9 51.0
23. 4.9 51.2
24. 5.1 51.3
25. 5.0 51.0
26. 4.8 51.1
27. 4.8 51.0
28. 4.8 51.0
29. 4.9 51.2
30. 4.7 51.1
SUPERHEATER HEADERS (INLET & OUTLET)

No.
1 Visual  Superheater headers (inlet & outlet) were visually
Examination inspected and found in satisfactory condition.
2 MPI  Magnetic particle inspection carried out for
circumferential weld joints. No significant surface or
sub-surface defect was observed.
3 DPT  Dye penetrant was carried on circumferential weld

joints, tube stub joints, attachment weld joints etc.
No significant surface defect observed.
4 UFD  Ultrasonic flaw detection carried out for
circumferential weld joints. No significant
discontinuity observed.
5 Dimensional  Dimensional measurement carried out. Details
measurement measurements have been furnished separately in
this chapter.
7 Replica  Microstructure reveals grains of ferrite and pearlite.
Degradation of pearlite phase is observed.
Degradation level IIL observed.
8 Hardness  Hardness measured on replica locations and
measured hardness found within acceptable limits.
SH O/L HEADER
THICK OD
1 34.6 N.A
2 35.0 N.A
3 34.4 N.A
4 35.6 N.A
Recommendation: Based on visual inspection, Magnetic particle Inspection,

Dye Penetrant test, Ultrasonic test, dimensional measurement,
metallographic analysis & hardness measurement, the components were
found in satisfactory condition & suitable for further operation. However, re-
inspection of component is recommended after 40,000 hrs. or 5 year of
operation to monitor the trend of service induced damage and assess its
fitness for further service as per IBR 1950 u/s. 391 A.

VISUAL INSPECTION REPORT
COMPONENT SUPERHEATER HEADERS (I/L TEST: VISUAL

& O/L) INSPECTION

Magnifying Glass
Flash Light
OBSERVATION
Sl. No. Component Interpretation Remarks
01 Superheater Superheater headers (I/L & O/L) Acceptable

headers (I/L &
were visually inspected. No
O/L)
significant abnormality could be
observed.
Result: Acceptable
MAGNETIC PARTICLE EXAMINATION
COMPONENT: SUPERHEATER TEST: MAGNETIC PARTICLE EXAMINATION

HEADERS (I/L & O/L)
Particular of Test: Wet fluorescent magnetic particle test
Surface Condition: Free from loose scale, dust, paint, oil & grease.
Surface was clean & dry
Lifting Capacity: AC-5Kg & HWDC-27Kg with yoke spacing
100mm
Type of Magnetic Particle: Wet fluorescent
Method of Magnetizing: Continuous Yoke
Direction of Field Longitudinal
Sensitivity Check Pie field Indicator
OBSERVATION
Sl.
No.
01 No surface or sub surface defect Acceptable

Circumferential welds
observed.
RESULT : Acceptable
DYE PENETRANT EXAMINATION
COMPONENT: SUPERHEATER HEADERS TEST: DYE PENETRANT EXAMINATION

(I/L & O/L)
1) Penetrant, Developer, Cleaner
2) Cleaning cloth
3) Magnifying glass
4) Inspection torch(light)
Dwell Time : 10-15 min Surface Condition : As cleaned

Development Time : 7 min Tested/Accepted : As per ASME sec V
Temp. Of component : 250-300
Approx.
OBSERVATION
Sl.
No.
Circumferential welds, No significant surface defect

01 Acceptable
stub joints, attachment observed.
welds etc.
RESULT : Acceptable
ULTRASONIC FLAW DETECTION
COMPONENT: SUPERHEATER HEADERS TEST: ULTRASONIC FLAW DETECTION

(I/L & O/L)
1) Ultrasonic Flaw Detector
2) Normal and Angle beam probe
3) Calibration block V1 & V2
4) Grease, Oil/ Mix
EQUIPMENT CLIBRATION Surface condition: As cleaned
Equipment calibrated by V1 & V2 Block Method : Direct Contact
PROBE SIZE FREQ. Range of Machine Settings
CRT
TECH. Dia MHz (mm) db Amp. Suppression
Angle 8 X 9 mm/ 2.5/4 0 - 300 48 80% Nil

450 Ф 10 mm
SCANNING LEVEL : + 6 dB RECORDING LEVEL : 50 % FSH &

ABOVE
OBSERVATION
Sl. Area of Examination Interpretation Remarks
No.
01 Circumferential weld joints No recordable indication observed. Acceptable
RESULT : Acceptable
FSH-2(LOC-1)
Sr no. THICK UT-O THICK UT-O OD
1. 6.50 <150 6.51 <150 51.0
2. 6.76 <150 6.60 <150 51.2
3. 6.96 <150 6.84 <150 51.0
4. 6.33 <150 6.43 <150 51.1
5. 6.70 <150 6.80 <150 51.2
6. 6.77 <150 6.65 <150 51.5
7. 6.33 <150 6.46 <150 51.0
8. 6.54 <150 6.64 <150 51.0
9. 6.62 <150 6.71 <150 51.2
10. 6.52 <150 6.60 <150 51.1
11. 6.76 <150 6.53 <150 51.3
12. 6.78 <150 6.61 <150 51.2
13. 6.43 <150 6.63 <150 51.1
14. 6.49 <150 6.64 <150 51.0
15. 6.79 <150 6.53 <150 51.2
16. 6.67 <150 6.54 <150 51.3
17. 6.92 <150 6.43 <150 51.2
18. 6.51 <150 6.52 <150 51.1
19. 6.67 <150 6.68 <150 51.1
20. 6.48 <150 6.67 <150 51.3
21. 6.68 <150 6.69 <150 51.1
22. 6.52 <150 6.64 <150 51.0
23. 6.84 <150 6.45 <150 51.0
24. 6.52 <150 6.81 <150 51.3
25. 6.98 <150 6.43 <150 51.2
26. 6.63 <150 6.53 <150 51.1
27. 6.45 <150 6.61 <150 51.0
28. 6.46 <150 6.47 <150 51.1
29. 6.42 <150 6.63 <150 51.2
30. 6.46 <150 6.59 <150 51.0
FSH-2(LOC-2)
Sr no. THICK UT-O THICK UT-O OD

1. 6.62 <150 6.45 <150 51.0
2. 6.80 <150 6.52 <150 51.0
3. 6.48 <150 6.62 <150 51.3
4. 6.37 <150 6.44 <150 51.1
5. 6.42 <150 6.57 <150 513.
6. 6.53 <150 6.62 <150 51.2
7. 6.46 <150 6.45 <150 51.2
8. 6.66 <150 6.47 <150 51.0
9. 6.41 <150 6.62 <150 51.2
10. 6.77 <150 6.57 <150 51.1
11. 6.56 <150 6.64 <150 51.1
12. 6.39 <150 6.47 <150 51.3
13. 6.61 <150 6.52 <150 51.1
14. 6.45 <150 6.72 <150 51.2
15. 6.69 <150 6.41 <150 51.1
16. 6.33 <150 6.53 <150 51.2
17. 6.84 <150 6.56 <150 51.3
18. 6.55 <150 6.50 <150 51.2
19. 6.76 <150 6.65 <150 51.3
20. 6.58 <150 6.71 <150 51.1
21. 6.96 <150 6.64 <150 51.1
22. 6.92 <150 6.52 <150 51.2
23. 6.96 <150 6.74 <150 51.0
24. 6.89 <150 6.58 <150 51.0
25. 6.58 <150 6.22 <150 51.2
26. 6.24 <150 6.56 <150 51.0
27. 6.54 <150 6.63 <150 51.3
28. 6.46 <150 6.53 <150 51.2
29. 6.51 <150 6.42 <150 51.1
30. 6.42 <150 6.63 <150 51.3
SH-1 COILS
SR NO. THICK UT-O OD
1. 5.3 <150 51.2
2. 5.4 <150 51.1
3. 5.0 <150 51.1
4. 5.1 <150 51.2
5. 5.0 <150 51.0
6. 5.2 <150 51.0
7. 5.1 <150 51.1
8. 5.3 <150 51.2
9. 5.4 <150 51.0
10. 5.2 <150 51.4
11. 5.3 <150 51.1
12. 5.4 <150 51.0
13. 5.3 <150 51.2
14. 5.4 <150 51.1
15. 5.4 <150 51.1
16. 5.6 <150 51.0
17. 5.4 <150 51.0
18. 5.2 <150 51.1
19. 5.3 <150 51.3
20. 5.0 <150 51.1
21. 5.6 <150 51.1
22. 5.5 <150 51.0
23. 5.4 <150 51.2
24. 5.2 <150 51.0
25. 5.4 <150 51.0
26. 5.0 <150 51.0
27. 5.2 <150 51.1
28. 5.6 <150 51.0
29. 5.3 <150 51.1
30. 5.4 <150 51.0


Surface condition Free from loose scale, dust, paint, oil & grease. Surface was
clean & dry.
Test Result:
No. tested
A Down Comer , Riser Tube , Saturated Tube
2 STUB JOINTS ALL No recordable Acceptable
discontinuity observed



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ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS

Intent of Study 17-38

Residual Life Assessment study of HRSG Page No. 1

We Energo Engineering Projects Limited extend our sincere thanks to the

We sincerely thank Director of Boilers , Uttar Pradesh for the valuable

We also appreciate the courtesy, help and co-operation extended by the

Dheeraj kumar Choudhary

Residual Life Assessment study of HRSG Page No. 2

For Energo Engineering Projects Limited

Dheeraj Kumar Choudhary

Residual Life Assessment study of HRSG Page No. 3

Objective of the study is to assess the present condition of various pressure

Residual Life Assessment study of HRSG Page No. 4

Executive summary Table

Sr. Boiler Tests

10.Econo VI In visual inspection carried out at Satisfactory Re -RLA

Residual Life Assessment study of HRSG Page No. 5

OD Outer dimension carried out at Economiser Satisfactory

13.Evapor VI In visual inspection carried out at Satisfactory

04. UT-T Thickness measurement carried out at LP Satisfactory

OD Outer dimension carried out at LP Satisfactory

16.De VI Visual inspection carried out at De Satisfactory Re -RLA

OD Outer dimension carried out at De Satisfactory

19. RPL/HB In situ metallogaraphic carried out at Microstructur

UT UT carried out at circumferential weld joints. Satisfactory

DPT DPT carried out at circumferential joints. No Satisfactory

Residual Life Assessment study of HRSG Page No. 6

swell swell measurement in the permissible limit Satisfactory

Residual Life Assessment study of HRSG Page No. 7

40.Feed VI Visual inspection carried out at Feed water OK Re -RLA

Residual Life Assessment study of HRSG Page No. 8

Kribhco shyam fertilizers limited shahjahanpur appointed Energo Engineering

Remaining Life Assessment (RLA) of HRSG boiler Unit # 1 (100MTPH), KSFL

Site activity commenced on 05/7/2017 and completed on 08/7/2017. All the

Residual Life Assessment study of HRSG Page No. 9

The Kribhco Shyam Fertilizers HRSG # 1 is of Thermax Babcock & Wilcox

Type of Unit : Natural Circulation

Residual Life Assessment study of HRSG Page No. 10

The objectives of Residual Life Assessment Study of THERMAX BABCOCK

Kribhco Shyam Fertilizersare as follows :

1. To establish the present condition of Boiler Pressure Parts.

2. To project the remaining useful life of Pressure Parts.

3. To provide realistic and practical recommendations for Run,

Repair and Replace if required.

4. To provide steps for reliable and safe operation.

5. To reduce the forced outages due to failures of pressure parts

and to achieve maximum boiler availability.

Residual Life Assessment study of HRSG Page No. 11

NOTE ON DAMAGE MECHANISM OF STEAM GENERATOR

Material selection in HRSG boiler construction varies within the boiler,

Boiler-Tube Failure Mechanisms

 Lack of quality control.

A. Stress-Rupture, and Thermal Fatigue are specifically related to the

Residual Life Assessment study of HRSG Page No. 12

a) Internal blockage of the tube.

In general short term over heating failures involve considerable tube

 High Temperature Creep: -

a) Internal restriction of tube coolant flow by scale, debris, or

High temperature creep usually results in a longitudinal fractured in the

B. Water Side Corrosion: -

Residual Life Assessment study of HRSG Page No. 14

Header Damage Mechanisms

2.0 APPROACH FOR RLA STUDY

A Study of the plant maintenance and operating records in