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Gtrack v 3.5

Inspection Report Created on 7/26/2006 9:34 a7/p7

Page 1Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant

AREA: Reheat Front Pendant

By: UDC Inspection Team The area was numbered from boiler left (west) side to

boiler right (east) side. Tubes were counted from front

(south) to rear (north) or top to bottom unless otherwise

specified.

Items were marked with white grease stick.

=====================================================================================P R I O R I T Y # A R E P A I R S

===================================================================================== Repair item #: 1Area: Reheat Repair #: 1-a Record:# 372

Action: TUBE REPLACEMENT

Priority #: A

General location is Reheat, Front Pendants,IR-7.Specific location: Tube #:12 Element #:141Elevation: 1457'Length: 5' Cause: Erosion (soot blower)Appearance: Polished Material: 2.25" OD x .148" MWT x SA-213TP304H The UT Result is .094

Due to wall loss from erosion, replace tube 12 (trailing tube) ofassembly 141. From the centerline of the bend, the lower cut line willbe 21” upward extending for a total length of 6’ 2”.

This tube replacement will not include the lower radius bend.

Work Order: _____________

Status: Work Completed – Assy 141 Replaced-------------------------------------------------------------------------------------

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Repair #: 1-b Record:# 371


Priority #: A General location is Reheat, Front Pendants,IR-7.Specific location: Tube #:12 Element #:2Elevation: 1457'Length: 7' Cause: Erosion (soot blower)Appearance: Polished Material: 2.25" OD x .148" MWT x SA-213TP304H

The UT Result is 0.069”

Due to wall loss from erosion, replace tube 12 (trailing tube) ofassembly 2. Measured from the centerline of the radius bend, the lowercut line on the horizontal section is 18” and the upper cut line is 7’.

The UT result @ the radius bend was 0.107”.

Work Order: _____________ Status: Work Completed – Assy 12 Replaced------------------------------------------------------------------------------------- Repair #: 1-c Record:# 375


Priority #: A General location is Waterwall North, HangerTubes, IR-7.Specific location: Tube #:106 through 107Elevation: 1457' Cause: Erosion (soot blower)Appearance: Eroded Tubing .320" MWT

The UT Result is .169 Tube 107 has 48% wall loss and tube 106 has 25% wall loss. Tube 106also has an old attachment that has an erosion gouge under it fromblower channeling. These tubes are to be replaced just below this areawith the replacement of the upper slope. Add at least 4’ of tubematerial to these 2 tubes when they are replaced below. Work Order: _____________

Status: Work Completed – Assy 106 and 107 Replaced-------------------------------------------------------------------------------------

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Repair item #: 2Area: Extended Side Wall Repair #: 2-a Record:# 381

Action: PAD WELD

Priority #: A General location is Extended Side Wall, WestSide, Top.Elevation: 1485'Length: .3' Cause: Erosion (fly ash)Appearance: Eroded

Apply a 3" x 2" pad weld to the side wall located adjacent to the watercooled spacer tube as it descends from the roof penetration. Repair islocated approximately 2' down from the roof line. Use vertical stringers and feather edges. Do not horizontal weave padweld. Down hand is suggested to keep the temperature as cool aspractical. Do not pad weld if copper deposition is present on theinternal surface of the tubing. Use TIG if the tube remaining wall isless than .125". Work Order: _____________

Status: Work Completed – Sidewall tube pad weld repaired------------------------------------------------------------------------------------- Repair #: 2-b Record:# 406

Action: PAD WELD

Priority #: A General location is WaterwallNorth, Hanger Tubes, IR-6.Specific location: Tube #:1Elevation: 1475'Length: 1.5' Cause: Erosion (soot blower)Appearance: Eroded Tubing

.320" MWT

The UT Result is .230

Apply a 17” pad weld on the trailing side of hanger tube 1 centered in IR-6 blowerpath. Work Order: _____________

Status: Work Completed – Tube 1 was pad weld repaired-------------------------------------------------------------------------------------

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=====================================================================================P R I O R I T Y # B R E P A I R S

===================================================================================== Repair item #: 3Area: Reheat

Repair #: 3-a Record:# 370 Action: SHIELD INSTALLATION REPAIR

Priority #: B General location is Reheat, Front Pendants,IR-6.Specific location: Tube #:11 Elements #:1

through 142Elevation: 1475'Length: 4' Cause: Erosion (soot blower)Appearance: Polished Material: 2.25" OD x .148" MWT x SA-213TP304H The UT Result is below 85% MWT Blower path 6 has eroded tube 11 (the trailing tube) throughout thefront pendants. UT readings were taken randomly and the results showedconsistent wear averaging .117 inches. It is recommended to shield thepath with a 4 foot minimum length shield that fits tight to the tubing.Clean tubing well before installation to ensure the maximum life of theshield. Follow the blower path allowing for sag towards the middle ofthe furnace. Repair by installing shield(s). Do not tack to tube in more than onelocation. Orient shield in the direction of possible erosion. Slantshields to match droop of soot blower lance. Weld with 7018 or inconel. Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------

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Action: SHIELD INSTALLATION REPAIR

Priority #: B General location is Waterwall North, HangerTubes, IR-6.Specific location: Tube #:55Elevation: 1475'Length: 4' Cause: Erosion (soot blower)Appearance: Eroded Tubing .320" MWT

The UT Result is .266 Shield tube for a minimum of 4 feet centered on the erosion area.

Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------

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Repair #: 3-c Record:# 378


Priority #: B General location is Reheat, Middle CrossoverSection. Cause: Abrasion Damage or Mechanical RubAppearance: Abraded Material: 2.25" OD x .148" MWT x SA-213TP304H

Install a 6" section of shielding encompassing the abraded area on the

following middle horizontal crossover assemblies/tube #:

12/1(UT-.126)21/224/127/231/248/1

In addition, install an 10" section of shielding on the rear wall hanger tubesadjacent to the noted reheat tubes. All abraded areas were visually identified andwere estimated to be below 85% of MWT. The middle horizontal crossover tubes werecounted top to bottom.


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Repair #: 3-d Record:# 382 Action: SHIELD INSTALLATION REPAIR

Priority #: B General location is Reheat, Upper CrossoverSection. Cause: Abrasion Damage or Mechanical RubAppearance: Abraded Material: 2.25" OD x .148" MWT x SA-213TP304H

Install a 6" section of shielding encompassing the abraded area on the

following upper horizontal crossover assemblies/tube #: 14/1 and 18/1.In addition, install a 15" section of shielding on the rear wall hangertubes adjacent to the noted reheat tubes. All abraded areas werevisually identified and were estimated to be below 85% of MWT. Theupper horizontal crossover tubes were counted bottom to top. Once thearea is spread open for repair, inspect the condition of tubes 2 and 3and apply repair criteria.


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Repair #: 3-e Record:# 384


Priority #: B General location is Reheat, Middle CrossoverSection. Cause: Abrasion Damage or Mechanical RubAppearance: Abraded Material: 2.25" OD x .148" MWT x SA-213TP304H

Install an 8" shield encompassing the side of the radius bend on

horizontal crossover tube 1 of assembly 15 at the point of intersectionwith assembly 14. In addition, install a 6" section of straight shieldon tube 2 of assembly 14. All abraded areas were visually identifiedand were estimated to be below 85% of MWT. (Assembly 14 tubes werecounted north to south; middle crossover tubes were counted top tobottom.)


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Repair #: 3-f Record:# 410 Action: SHIELD INSTALLATION REPAIR

Priority #: B General location is Reheat, Front Pendants,IR-7.Specific location: Tube #:12 Elements #:128through 129Elevation: 1457'Length: 4' Cause: Erosion (soot blower)Appearance: Polished Material: 2.25" OD x .148" MWT x SA-213TP304H

The UT Result is .122 & .118

Shield tube 12 (trailing side tube) of assembly 128 on the north sideface centered on blower path 7R.


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Repair #: 3-g Record:# 476


Priority #: B General location is Reheat, Front Pendants,IR-7.Specific location: Tube #:12 Elements #:76through 77Elevation: 1457'Length: 4' Cause: Erosion (soot blower)Appearance: Polished

Material: 2.25" OD x .148" MWT x SA-213TP304H The UT Result is .108 & .122

Shield tube 12 (trailing side tube) of assemblies 76 and 77 on thenorth side face centered on blower path 7R. Assembly 76 tube has justexceeded the 75% MWT.


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Repair #: 3-h Record:# 477 Action: SHIELD INSTALLATION REPAIR

Priority #: B General location is Reheat, Front Pendants,IR-7.Specific location: Tube #:12 Element #:73Elevation: 1457'Length: 4' Cause: Erosion (soot blower)Appearance: Polished Material: 2.25" OD x .148" MWT x SA-213TP304H

The UT Result is .110 Shield tube 12 (trailing side tube) of assembly 73 on the north sideface centered on blower path 7R.


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Repair #: 3-i Record:# 478



The UT Result is .118

Shield tube 12 (trailing side tube) of assembly 4 on the north sideface centered on blower path 7L.


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Repair #: 3-j Record:# 475 Action: SHIELD INSTALLATION REPAIR


The UT Result is .118 Shield tube 12 (trailing tube) of assembly 80 on the north side facecentered on blower path 7R.


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Repair item #: 4Area: Roof Tubes

Repair #: 4-a Record:# 383 Action: ALIGN AND RE-ATTACH

Priority #: B General location is Roof Tubes, West Side.Specific location: Tube #:1Elevation: 1487'Length: 12' Appearance: Bowed Tubing

Pull first roof tube back up into position, attach support clips tocollector bars, and restore refractory layer above. The tube is boweddown at the crossover section for a run of approximately 10 - 15 feet.


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Repair item #: 5Area: Reheat

Repair #: 5-a Record:# 424 Action: FLEX TIE REPLACEMENT

Priority #: B General location is Reheat, Front Pendants,Specific location: Tube #:1 Element #:98

Elevation: 1455' Cause: Fatigue (thermal)Appearance: Broken

Material: 2.25" OD x .148" MWT x SA-213TP304H Replace flex tie between tube 1 & 2 located approximately 5' up fromthe bottom loop of the pendant. It is recommended to clean the frontof pendant and grant access to thoroughly inspect for cracked ormissing flex ties, etc. Try to install the new clips in other locations from the original heataffected zone. Weld with tube 7018 or inconel.


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Repair #: 6-a Record:# 392 Action: ROD-OUT ACCUMULATION (P2)

Priority #: B General location is Reheat, @ Reheat MiddleCrossover Section.Elevation: 1484' Appearance: Blocked Gas Lane

It appears that the ash accumulation at the top section of thefront/rear reheat pendant is plugged approximately 60% from left toright side. The pluggage extends down approximately 6' from the roofline. Ash accumulation and slagging characteristics such as thisindicate a high fouling rate, low fusion point consistency throughoutcomponent. These characteristics are more prevalent with a low BTUburning fuel, such as Powder River Basin. To reduce high fouling, andto increase ash fusion temperatures, it is recommended to consider thefollowing options: Blend coal with a bituminous to increase BTU, and/orde-slag the waterwalls. Removing the slag build up from the waterwallswill increase heat transfer in the fire box, therefore, reducingfouling points in the pendant paths etc. Less pluggage and slag buildup would be evident throughout the pendants.


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=====================================================================================P R I O R I T Y # C R E P A I R S

===================================================================================== Repair item #: 7Area: Roof Tubes

Repair #: 7-a Record:# 386 Action: PEG FIN REPLACEMENT

Priority #: C General location is Roof Tubes, @ front reheatpendant.Specific location: Element #:7

Elevation: 1487' Cause: Fatigue (thermal)Appearance: Burnt or Distorted

It appears that the peg fin located between the front pendant tubes atthe roof tube intersection is fatigued and burnt away. This fatigue hasallowed the refractory to degrade and for temperatures to increase atthe penthouse seal box locations. It is evident that slag accumulationsare blocking access to inspect several additional elements at the roofpenetration. It is recommended to remove ash build up at this locationto inspect for all fatigued areas. Remove existing peg fin remnants and replace with new. Install finswith non-continuous side against tube and apply short welds notextending past each fin break.


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Repair #: 8-a Record:# 394 Action: REMOVE ASH AND DEBRIS

Priority #: C General location is Reheat, @ top crossover.Elevation: 1483' Appearance: Ash build up The top section of the reheat crossovers couldnot be inspected due to excessive ash build

up. UDC recommends that this debris be removedfor a 100% visual inspection.

Work Order: _____________ Status: Not Inspected-------------------------------------------------------------------------------------

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Repair #: 9-a Record:# 376 Action: MONITOR CLOSELY

Priority #: C General location is Reheat, Spacer Tube, Top.Elevation: 1485' Cause: Erosion (soot blower)Appearance: Eroded Material: 2.0" OD x .240" MWT x SA-210A1

Monitor erosive wear located on the bottom edge of the WCS tubes asthey bend at the West wall. Damage is located approximately 2' downfrom the roof line. Lowest UT result found was on the bottom tuberesulting in .204". Monitor this item during future overhauls.

Work Order: _____________ Status: Inspected------------------------------------------------------------------------------------- Repair #: 9-b Record:# 380

Action: MONITOR CLOSELY

Priority #: C General location is Extended Side Wall, @Reheat Middle Crossover Section. Appearance: Eroded

Located within the reheat middle crossover section, erosion isoccurring on both the WCS tube and the west sidewall tube at the pointof intersection. Monitor this item during future overhauls; repaircriteria does not apply at this time.


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Repair #: 9-c Record:# 385 Action: MONITOR CLOSELY

Priority #: C General location is Roof Tubes, @ ReheatMiddle Crossover Section.Specific location: Tube #:1Elevation: 1485' Cause: Erosion (soot blower)Appearance: Eroded

Monitor erosion on the bottom edge of roof tubing at the crossoverintersection as well as to the front of the front reheat pendant.

Work Order: _____________ Status: Inspected------------------------------------------------------------------------------------- Repair #: 9-d Record:# 397

Action: MONITOR CLOSELY

Priority #: C General location is Reheat, @ Reheat MiddleCrossover Section.Elevation: 1482' Cause: Abrasion Damage or Mechanical RubAppearance: Abraded

It appears that the intersection of the North waterwall hanger tubesand the middle reheat crossover tubes are abrading. Monitor thisintersection during every scheduled shut down, and make repairs as

inspection results indicate.


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Repair #: 9-e Record:# 421 Action: MONITOR CLOSELY

Priority #: C General location is Reheat, Front Pendants,Front.Elevation: 1449' Cause: Erosion (soot blower)Appearance: Polished

It appears that the inner radius bends of the front/bottom loops are

showing signs of erosive polishing. UT results indicate that tubes arestill well above design MWT. No repairs are necessary at this time,monitor during future shut downs.


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Repair #: 9-f Record:# 423 Action: MONITOR CLOSELY

Priority #: C General location is Waterwall Division, @ Archnose, West side.Elevation: 1448' Cause: Erosion (fly ash)Appearance: Polished

Monitor erosive wear located at the arch nose intersection. Erosionpattern appears to exist on the tubes just to the front of the arch, v

Work Order: _____________ Status: Inspected

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Repair #: 9-g Record:# 389 Action: MONITOR CLOSELY

Priority #: C General location is Roof Tubes.Elevation: 1487' Cause: Erosion (fly ash)Appearance: Eroded

Monitor erosive wear located on the roof tubes from the SH platens backto the reheat front pendants. It is recommended that these locations beinspected thoroughly once scaffolding/access is granted. It appears

that the roof tubes adjacent to the platens and pendants are showingmore wear.

Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------vRepair item #: 10Area: Reheat Repair #: 10-a Record:# 379

Action: INFORMATION ONLY

Priority #: C General location is Reheat, Middle CrossoverSection. Appearance: Ash Accumulation Material: 2.25" OD x .148" MWT x SA-213TP304H

Due to the amount of fused ash on the Upper Horizontal Crossoversection, a thorough inspection for abrasion damage could not beconducted. It is recommended that the area be cleaned thoroughly andre-inspected during the next planned overhaul.


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Action: INFORMATION ONLY

Priority #: C General location is Reheat, Front Pendants,IR-7.Specific location: Tube #:12Elevation: 1453' Appearance: Out of alignment Material: 2.25" OD x .148" MWT x SA-213TP304H On assemblies 64 and 136, the lower loop is out of alignment by 3/4

tube diameter.


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