Serving the Power Industry

Since 1979
EPRI 2008

Boiler Inspection (an inexpensive means to increased

availability)

The causes of plant unavailability are well defined, and sound

technology-based solutions are available to improve plant
availability.

Utilities have many opportunities to increase electrical output

at existing units without increasing fuel burn. This can be
achieved by improving efficiency or reducing forced outages
through component inspection, repair, or in the extreme
replacement. In some cases, utilities do so as a reaction to unexpected component failures
(reactive replacement). In other cases utilities replace worn or aging components which are
inspected and analyzed and have expectation of failure in the future or whose performance is
deteriorating (predictive replacement).

The typical boiler outage project process is to back fit the work flow or logic into a given timeframe
as developed. Sometimes this timeframe is up to 10 years ahead, based on constraining
completion times for the project and with consideration of resource constraints. The best practices
have been the identification of risks (boiler discovery inspection results) which begin during the
early stages of a project. The critical element is the quality and quantity of the inspections and
their results.

The process of cost containment is not just a reduction of total costs. Cost control can only be
effective if we focus the funds available in a surgical manner. Less money does not necessarily
translate into lower availability. Discovery inspection results (data), can be used to focus the
money allotted in the most productive areas with the highest risk of failure.

Boiler inspectors and inspection teams

Management has historically underestimated the quality

and quantity of discovery inspection personnel. The
selection process of “Just get some folks from where you
can and put them in there” has to be rethought. One of
the first areas of budget reduction is the inspection scope
of work. Inspection should be the last budget item cut. It’s
like driving in the dark with no map and no lights.
Unfortunately old habits and methods die hard. Just
because we have always done it that way doesn’t make it
the best way.

United Dynamics Corporation ■ 2681 Coral Ridge Road ■ Brooks, KY 40109 ■ Voice 502.957.7525 ■ Fax 502.957.5441
Serving the Power Industry
Since 1979
Inspectors should be thoroughly trained and
seasoned before their full implementation into a
boiler inspection team. Far too much is reliant on the
inspector and their recommendations.

While building an in-house inspection team there are

third party resources which can provide qualified and
seasoned boiler inspection services. The hands on
training from a provider employee to your inspection
staff can prove to be invaluable when combined with
formal class room training.

We have many examples of boiler availability improvement, founded by increased discovery

inspections, when performed by qualified personnel.

Whether you recruit from within your organization, or from other resources, it will be difficult to
obtain individuals with the technical background who are willing to do detailed discovery
inspections. This is further aggravated by a shortage in available resources.

A recent study by Krishnan & Associates on the aging workforce trends at U.S. coal-fired power
plants, the cornerstone of the nation’s power supply, found that the average age of the workforce
at these power plants is 48.

In its nationwide survey from 2005, K&A

concluded that an average coal-fired plant will
likely lose half its current plant staff in the next
decade due to retirement and attrition. The study
concludes that the specialized labor to replace this
talent pool will likely be in short supply and
difficult to recruit.

According to a study by Hay Group, a global

organizational and human resources consulting
firm, a substantial number of mission-critical
employees in the utilities industry from the
executive suite down to the boiler inspector are rapidly approaching retirement age.

The study also found that on average these employees are older than their counterparts in other
industries and represent approximately 50% to 60% of the power industry’s knowledge assets.

The study showed this issue goes way beyond human resources issues of retirement, recruitment,
and retention. The results revealed a need for a comprehensive approach which includes academia.
The utility industry’s staffing problems start at the undergraduate level. Universities are now
graduating an average of 10 power engineers per state per year, compared to 2000 graduates in
the 1980s. In contrast, such countries as India, China, and Russia graduate a significant number of
power engineers each year.

United Dynamics Corporation ■ 2681 Coral Ridge Road ■ Brooks, KY 40109 ■ Voice 502.957.7525 ■ Fax 502.957.5441
Serving the Power Industry
Since 1979
Surprisingly, salaries are more than competitive, with senior power engineers earning 30 to 40
percent more than computer science engineers. Yet today’s most talented, promising students are
focused and directed toward careers in aerospace, biotechnology, software development, and
chemical engineering.

Diversity is also an issue. According to the National Academy of Engineers, the number of women
in engineering is declining. Women account for less than 17 percent of engineering graduates
compared to 20 percent a few years ago.

One successful solution has been to outsource the weakness in

technical talent and experience with personnel provided from a
third party. Don’t confuse these provider services with temporary
help firms. To insure quality and dependability of supplied staff,
the personnel must be full time employees of the provider. The
provider has the overall responsibility of recruiting, training and
seasoning of staff. This supplementation would include disciplines
such as outage managers, technical engineering, planning, and
inspection resources. Turn on the talent when needed and turn
off when not needed. This is not only cost effective for the user
but allows the provider to utilize their resources across many
companies. This efficiency allows for competitive pricing to all
users. Compensation of provider staff by the provider is usually highest in the industry to maintain
a sufficient supply of qualified provider resources. In many cases provider employees are former
utility retirees.

Outsourcing examples

Boiler operating reliability is becoming more and more of a necessity as we recognize the growth
rate of our population world wide, and the difficulties of gaining rights for new fossil fueled unit
construction. As a result of this supply and demand swing, aside from alternative energy
production including renewable fuel sources, availability of our existing fleet is becoming not just a
desired goal, but a necessary one. Outside boiler inspection consulting firms play an integral role in
the overall plan for continued unit operation and efficiency.

As an outside provider for boiler inspections, as well as providing boiler tube failure metallurgical
analysis, UDC(United Dynamics “AT” Corp)/DNFM (David N French Metallurgists) services have
been utilized from one end of the consulting spectrum to the other. There are clients who request
services that will only include evaluation of one component or piece of auxiliary equipment; these
customers wish not to tie up large amount of funding for inspections, they simply want to utilize
our services for a specific purpose. These types of projects are usually wrapped up in a day or two
and a report depicting, as well as identifying results is given prior to representative leaving the job.
Some of our customers simply request verbal information not requiring our presence on the job.

On the other end of the spectrum there are customers who utilize our services to maximize their
inspection benefit. The services requested include pre-outage preparation involving upcoming
inspection matrix solutions, budgetary concern assistance, engineering methods of repair
proposals, scaffold location recommendations, outage time tables and schedule support, contractor

United Dynamics Corporation ■ 2681 Coral Ridge Road ■ Brooks, KY 40109 ■ Voice 502.957.7525 ■ Fax 502.957.5441
Serving the Power Industry
Since 1979
management assistance, unit walk-down inspections prior to shut
down and during shut down. Other services involve dirty
inspections, report writing, follow up including QAQC work, track
record of repairs performed and completed as well as repairs not
completed, generation of a final report indicating all repair work
performed, all repair work not performed each listed by priority
for the next outage matrix, as well as any and all
recommendations and comments to assist in the overall efficient
and consistent operation of the unit.

Training of staff

Many companies are behind in the succession or “mentoring” process. Traditionally we would bring
in a prospective replacement several years before technical and management employees actually
leaves. This lack on mentoring, places an additional burden on maintenance system. The process of
bringing a new employee up to speed while maintaining the intensity and efficiency of outages can
be problematic.

Training courses are available in-plant and public addressing topics including;

• Boiler fundamentals

• Basic Boiler inspection techniques

• Advanced boiler inspection techniques

• Outage management and planning and budgets

• Boiler failure root cause analysis

• Implementing a Boiler tube failure reduction program

• Operators impact on boiler failures

• In many cases the use of outsourcing can be used initially followed up by formal training
regimes.

United Dynamics Corporation ■ 2681 Coral Ridge Road ■ Brooks, KY 40109 ■ Voice 502.957.7525 ■ Fax 502.957.5441
Serving the Power Industry
Since 1979

A training sample taken from UDC Boiler

Inspection Techniques Level I follows;

Various schemes of power

generation and steam use

Conventional fossil steam plant:

Generating units vary in size. Fossil-fuel steam-electric units typically have large
capacities with many to 1,300 megawatts (MW). Gas turbines, combustion turbines, and
combined-cycle units are typically less than 200 MW, but some are larger.

The generating units operated by an electric utility vary by intended usage, that is, by the
three major types of load (generally categorized as base, intermediate, and peak)
requirements the utility must meet.

A base-load generating unit is normally used to satisfy all or part of the minimum or base
load of the system and, as a consequence, produces electricity at an essentially constant
rate and runs continuously. Base-load units are generally the largest of the three types of
units, but they cannot be brought on line or taken off line quickly. Peak-load generating
units can be brought on line quickly and are used to meet requirements during the periods
of greatest or peak load on the system. They are normally smaller plants using gas and
combustion turbines. Intermediate-load generating units meet system requirements that
are greater than base-load but less than peak load. Intermediate-load units are used
during the transition between base-load and peak-load requirements.

Steam-electric (thermal) generating units are typically the large base load plants.

Steam produced in a boiler turns a turbine to drive an electric generator. Fossil fuels (coal,
petroleum and petroleum products, natural gas or other gaseous fuels) and other
combustible fuels, such as biomass and waste products, are burned in a boiler to produce
the steam.

The thermal efficiency of fossil-fueled steam-electric plants is about 33 to 35 percent. The

waste heat is emitted from the plant either directly into the atmosphere, through a cooling

United Dynamics Corporation ■ 2681 Coral Ridge Road ■ Brooks, KY 40109 ■ Voice 502.957.7525 ■ Fax 502.957.5441
Serving the Power Industry
Since 1979
tower, or sent to a lake for cooling. A water pump brings the residual water from the
condenser back to the boiler.

United Dynamics Corporation ■ 2681 Coral Ridge Road ■ Brooks, KY 40109 ■ Voice 502.957.7525 ■ Fax 502.957.5441
Serving the Power Industry
Since 1979

Gas Turbines:
Gas turbines and
combustion engines use the
hot gas from burning fossil
fuels, rather than steam, to
turn a turbine that drives
the generator. These plants
can be brought up quickly,
and so are used as peaking
plants. The number of gas
turbines is growing as
technological advances in gas turbine design and declining gas prices have made the gas
turbine competitive with the large steam-electric plants. However, thermal efficiency is
slightly less than that of the large steam-electric plants The gas wastes are disposed of
through an exhaust stack.

Cutaway of Combustion Turbine

United Dynamics Corporation ■ 2681 Coral Ridge Road ■ Brooks, KY 40109 ■ Voice 502.957.7525 ■ Fax 502.957.5441
Serving the Power Industry
Since 1979

Combined-Cycle
Units:
Combined cycle plants first
use gas turbines to
generate power and then
use the waste heat in a
steam-electric generator to
produce more electricity.
Thus, combined-cycle
plants make more efficient
use of the heat energy in
fossil fuels. New
technology is improving
the thermal efficiency of
combined-cycle plants,
with some reports of 50 to
60 percent thermal
efficiency.

United Dynamics Corporation ■ 2681 Coral Ridge Road ■ Brooks, KY 40109 ■ Voice 502.957.7525 ■ Fax 502.957.5441
Serving the Power Industry
Since 1979

Co generating Units:
Co generators, also known as combined heat and power generators, are facilities that
utilize heat for electricity generation and for another form of useful thermal energy (steam
or hot water), for manufacturing processes or central heating. There are two types of
cogeneration systems: bottom-cycling and top-cycling. In a bottom-cycling configuration, a
manufacturing process uses high temperature steam first and a waste-heat recovery
boiler recaptures the unused energy and uses it to drive a steam turbine generator to
produce electricity. In one
of two top-cycling
configurations, a boiler
produces steam to drive a
turbine-generator to
produce electricity, and
steam leaving the turbine
is used in thermal
applications such as space
heating or food
preparation. In another top-
cycling configuration, a
combustion turbine or
diesel engine burns fuel to
spin a shaft connected to a
generator to produce

electricity. The waste heat

United Dynamics Corporation ■ 2681 Coral Ridge Road ■ Brooks, KY 40109 ■ Voice 502.957.7525 ■ Fax 502.957.5441
Serving the Power Industry
Since 1979
from the burning fuel is recaptured in a waste-heat recovery boiler for use in direct
heating or producing steam for thermal applications.

United Dynamics Corporation ■ 2681 Coral Ridge Road ■ Brooks, KY 40109 ■ Voice 502.957.7525 ■ Fax 502.957.5441
Serving the Power Industry
Since 1979
A training sample taken from UDC Boiler Inspection Techniques Level II follows.

LOWER SLOPE HORIZONTAL TUBES & ASH PIT

1. Inspect under the throat scaffolding for continuation of dents and gouges from slag fall.

2. Water in the ash hopper may cause:

3. Quench cracking in the tubes (thermal stress)

4. Membrane cracking between the under slope tubes.

5. Rough water in the ash pit may be caused by falling slag creating waves and splashing
conditions. Overflow boxes should be designed to handle excessive amounts of water as
well as proper water level maintained.

6. Inspect for weld cracks at the scallop bar where the tubes exit the hopper wall, and at all
welds directly between the tubes and any attachment.

7. All membrane cracking, erosion and abrasion must be repaired according to remaining wall
criteria. All cracking must be ground out and welded.

Inspect the water seal trough

Record any

1. Corroded plates or lining

2. Cracked welds (indicating possible expansion

problems)

3. Missing or broken drain and vent piping

4. Ash & debris accumulation.
5. Structural integrity.
6. Water seal trough must be intact and clear of
Debris found in a seal trough
debris.

Inspect the seal plate.

Record any

1. Corrosion
2. Holes or deformations
3. Cracks
4. Bent or broken stitch welds
The is a radiation shield from a CE type boiler

United Dynamics Corporation ■ 2681 Coral Ridge Road ■ Brooks, KY 40109 ■ Voice 502.957.7525 ■ Fax 502.957.5441
 Serving the Power Industry
Since 1979

Exposed manifold piping Excessive ash

accumulation in the
seal trough is
extremely corrosive
to the seal plate.

What is left of a seal skirt once corrosive material

has been cut and removed

1. All holes in seal plate should be patched. The seal skirt

should be straightened and aligned cold in seal trough.
Refractory cooling piping
2. A reflector plate may be installed

Inspect for deterioration of the refractory seal over the seal trough. This may take place
due to:

1. Differential expansion
2. Slag falls
3. The refractory should be replaced for pressurization, and slag falls minimized. Combustion
should be optimized to help curtail the differential expansion.

Inspect all drip screens

1. Record any missing or deteriorated (tears or

holes) as well as missing, burnt or broken
brackets.

2. Eroded and distorted drip screens should be

removed and replaced. These screens protect
the boiler seal plate from splashing water, ash
entering into the trough and temperature.

Typical example of lower throat tubes

including drip screen member
Refractory anchor horns

United Dynamics Corporation ■ 2681 Coral Ridge Road ■ Brooks, KY 40109 ■ Voice 502.957.7525 ■ Fax 502.957.5441
Serving the Power Industry
Since 1979

Inspect exposed header stub welds for:

1. Quench cracking
2. Differential expansion fatigue cracking at toe of weld

The photograph below shows the lower side of the

horizontal slope tubes and drip screen.
Radiation shield attachment to the under
slope tubes

Depiction of typical quench cracking at the

weld to tube location on a sidewall inlet
header exposed to bottom ash splashing

Inspect the hopper bottom refractory and record:

1. Cracked, spalled, eroded or missing refractory, buckling in hopper walls.

Inspect all Jetting nozzles and record:

2. Plugged nozzles
3. Eroded nozzles or nozzle shields
4. Nozzle position.
5. Note that the measured diameter should not exceed 1/8" over the original ID. Please note that
nozzles must be directed parallel to walls.

Inspect Inward overflow/header heat shield and

record:

6. Cracks in directional plate

7. Plugged nozzles
8. Erosion

Inspect Crickets between two hoppers and record

9. Missing or cracked angle iron

10. Refractory on cricket.
Photograph shows an overflow box
with the refractory
removed.
Inspect the hopper water over flow weir box and record:
11. Any sediment build up
12. Corrosion of the weir box itself.

United Dynamics Corporation ■ 2681 Coral Ridge Road ■ Brooks, KY 40109 ■ Voice 502.957.7525 ■ Fax 502.957.5441