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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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Page 2Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
Repair #: 1-b Record:# 371
Action: TUBE REPLACEMENT
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
Action: TUBE REPLACEMENT
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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Page 3Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
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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Page 4Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
=====================================================================================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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Page 5Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
Repair #: 3-b Record:# 377
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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Page 6Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
Repair #: 3-c Record:# 378
Action: SHIELD INSTALLATION REPAIR
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.
Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------
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Page 7Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
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.
Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------
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Page 8Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
Repair #: 3-e Record:# 384
Action: SHIELD INSTALLATION REPAIR
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.)
Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------
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Page 9Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
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.
Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------
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Page 10Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
Repair #: 3-g Record:# 476
Action: SHIELD INSTALLATION REPAIR
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.
Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------
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Page 11Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
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.
Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------
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Page 12Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
Repair #: 3-i Record:# 478
Action: SHIELD INSTALLATION REPAIR
Priority #: B General location is Reheat, Front Pendants,IR-7.Specific location: Tube #:12 Element #:4Elevation: 1457'Length: 4' Cause: Erosion (soot blower)Appearance: Polished Material: 2.25" OD x .148" MWT x SA-213TP304H
The UT Result is .118
Shield tube 12 (trailing side tube) of assembly 4 on the north sideface centered on blower path 7L.
Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------
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Page 13Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
Repair #: 3-j Record:# 475 Action: SHIELD INSTALLATION REPAIR
Priority #: B General location is Reheat, Front Pendants,IR-7.Specific location: Tube #:12 Element #:80Elevation: 1457'Length: 4' Cause: Erosion (soot blower)Appearance: Polished Material: 2.25" OD x .148" MWT x SA-213TP304H
The UT Result is .118 Shield tube 12 (trailing tube) of assembly 80 on the north side facecentered on blower path 7R.
Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------
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Page 14Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
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.
Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------
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Page 15Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
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.
Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------
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Page 16Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
Repair item #: 6Area: Reheat
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.
Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------
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Page 17Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
=====================================================================================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.
Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------
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Page 18Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
Repair item #: 8Area: Reheat
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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Page 19Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
Repair item #: 9Area: Reheat
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.
Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------
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Page 20Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
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.
Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------
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Page 21Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
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.
Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------
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Page 22Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
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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Page 23Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
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.
Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------
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Page 24Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
Repair #: 10-b Record:# 479
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.
Work Order: _____________ Status: Inspected-------------------------------------------------------------------------------------