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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

ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS

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

Residual Life Assessment study of HRSG Page No. 2
Report No. F136/RLA/KRIBHCO/BLR1/07/2017

ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS

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

Residual Life Assessment study of HRSG Page No. 3
Report No. F136/RLA/KRIBHCO/BLR1/07/2017

F136/RLA/KRIBHCO/BLR1/07/2017 . 4 Report No. Magnetic particle inspection 4.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS 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. Visual Examination 2. Hardness measurement Residual Life Assessment study of HRSG Page No. Following Non-Destructive Tests were carried out during site RLA Study. In-Situ Metallography and Replication for lab study 8. Ultrasonic Thickness Measurement 6. 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. Ultrasonic test 5. Dimensional Measurement 7. In-Situ Oxide Scale Thickness Measurement 9. 1. Dye-Penetrant Test 3.

Drum Visual and externally exposed area. Magnetite layer -RLA Inspection found in satisfactory condition. will be carried Residual Life Assessment study of HRSG Page No. Drum internal Study found in satisfactory condition. UFD Ultrasonic flaw detection test carried out at Satisfactory circumferential and longitudinal weld joints. No crack or level-I & cavitation found. Conducted Findings / Observation Remark Six onent Visual inspection carried out at drum internally Satisfactory Re 01. No major abnormality Study tube observed. be DPT Dye Penetrant Test carried out at all Satisfactory carrie attachment weld joints. Satisfactory 10. Microstructur WM: Microstructure show predominent e show the structure of pearlite & farrite degradation PM: Microstructure show predominent between structure of pearlite & farrite. Comp. Boiler Tests No. Thin layer of will corrosion found on the outer surface. level-II Hardness WM:154 Satisfactory PM:122 Deposit Deposit sample collected for lab test.Econo VI In visual inspection carried out at Satisfactory Re -RLA 03. miser Economiser tube. Detailed enclosed Internal Internal Diameter carried out at drum Satisfactory Diameter Detailed enclosed RPL In situ metallogaraphic carried out at. circumferential & d out longitudinal weld joints. ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS Executive summary Table Sr. No surface defects after observed. No surface & subsurface defects observed. 5 Report No. No remarkable indication observed UT-T Thickness measurement carried out at shell Satisfactory and dish end. F136/RLA/KRIBHCO/BLR1/07/2017 . safety valve stub joints and drum ligament joints. Six MPI MPI carried out at circumferential weld joints & Satisfactory year longitudinal weld joints. detailed sample report Analysis enclosed.

Residual Life Assessment study of HRSG Page No. Detailed enclosed OD Outer dimension carried out at LP Satisfactory Evaporator tube. Detailed enclosed 13. UT-T Thickness measurement carried out at LP Satisfactory Evaporator tube. No crack or level-I & cavitation found. Satisfactory No Remarkable indication observed. Detailed enclosed 16.De VI Visual inspection carried out at De Satisfactory Re -RLA Superh Superheater exposed area . No major abnormality tube observed. eater observed. DPT DPT carried out at circumferential joints. F136/RLA/KRIBHCO/BLR1/07/2017 . No Satisfactory surface crack observed. ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS UT-T Thickness measurement carried out at Satisfactory out after Economiser tube. 04. no abnormality Study 06. will be carried UT-T thickness carried out at De Superheater.123 UT UT carried out at circumferential weld joints. Six year Detailed enclosed OD Outer dimension carried out at Economiser Satisfactory tube.143 PM:114. 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. level-II WM:134. 6 Report No.Evapor VI In visual inspection carried out at Satisfactory 0 ator Evaporator tube.

No crack or level-II cavitation found. No surface & subsurface defects observed. UT-O< 150 micron 36. out after MPI MPI carried out at circumferential weld joints Satisfactory Six year & all accessible stub joints. Steam observed on main steam line. 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. 7 Report No. VI Visual inspection carried out at Super heater Satisfactory Re -RLA tube. swell swell measurement in the permissible limit Satisfactory measurem ent 32. tube OD Outer diameter measurement carried out at Satisfactory will be SH header tube. UT-T Thickness measurement carried out at main Satisfactory steam line. No erosion observed. ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS swell swell measurement in the permissible limit Satisfactory measurem ent 23. F136/RLA/KRIBHCO/BLR1/07/2017 . 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.141 PM:111. Study 11. No remarkable indication observed. UTD Ultrasonic flaw detection test carried out at Satisfactory circumferential weld joints. No surface carried defect observed. 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. Study Residual Life Assessment study of HRSG Page No.120 30.Main VI In visual inspection no major abnormality Satisfactory Re -RLA 07. No erosion observed. Study Line DPT DPT carried out at circumferential weld Satisfactory will be joints & all accessible stub joints.SH VI Visual inspection carried out at SH header Satisfactory Re -RLA header tube.

ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS
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

Residual Life Assessment study of HRSG Page No. 8
Report No. F136/RLA/KRIBHCO/BLR1/07/2017

ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS
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.

Residual Life Assessment study of HRSG Page No. 9
Report No. F136/RLA/KRIBHCO/BLR1/07/2017

ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS
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

Residual Life Assessment study of HRSG Page No. 10
Report No. F136/RLA/KRIBHCO/BLR1/07/2017

: KSFL/SPN/M-O/S/6000201/PD/85000736 Dated 01/08/15 .ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS INTENT OF STUDY The objectives of Residual Life Assessment Study of THERMAX BABCOCK & WILCOX LTD PUNE make HRSG # 1 Pressure Parts (Reg. 2. Residual Life Assessment study of HRSG Page No. To project the remaining useful life of Pressure Parts. No. To establish the present condition of Boiler Pressure Parts. To provide realistic and practical recommendations for Run. Repair and Replace if required. 4.UP-5318) of Kribhco Shyam Fertilizersare as follows : 1. The RLA Study was carried out as per the guidelines of Indian Boilers Regulation Clause 391 (A). To provide steps for reliable and safe operation. 11 Report No. 3. 5. To reduce the forced outages due to failures of pressure parts and to achieve maximum boiler availability. (a) table 1 and also the detailed specific requirements of Kribhco Shyam Fertilizers Vide their Work Order No. F136/RLA/KRIBHCO/BLR1/07/2017 .

extruded tubes and vary all the way from carbon steel. two fundamental and common factors that dictate material selection are creep strength and resistance to oxidation at high temperatures. 12 Report No.  Welding defects.  Stress – Rupture. Boiler-Tube Failure Mechanisms Failure of boiler tubes is the foremost cause of the forced boiler outages.  Caustic corrosion.  High-temperature creep.  Short-term overheating.  Lack of quality control. Stress-Rupture. Although tubes and pipes have some unique problems of their own. The major failure categories in boiler tubes are listed as below. economics and availability of a component in the sizes required. Residual Life Assessment study of HRSG Page No.  Thermal.  Hydrogen damage.  Pitting (localized corrosion).  Vibration. A.where tube operating temperatures are in creep range. Failure by stress-rupture mechanisms are encountered predominantly in HT super heater .  Stress-corrosion cracking.  Dissimilar-metal welds.  Water-Side Corrosion.  Corrosion. finned.  Chemical excursion damage. stress rupture also can occur in LP tubing if abnormal heat transfer conditions result in an increase in tube operating temperature. and Thermal Fatigue are specifically related to the high temperature environment.  Fatigue.  Material defects.  Maintenance cleaning damage. However.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS EEPL APPROACH & RLA METHODOLOGY NOTE ON DAMAGE MECHANISM OF STEAM GENERATOR COMPONENTS Material selection in HRSG boiler construction varies within the boiler. Boiler tubes are seamless.. depending on duty requirements. F136/RLA/KRIBHCO/BLR1/07/2017 .

Just prior to a charge to a higher grade of steel.  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. 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. the tube will exhibit a higher creep rate and will fail earlier than expected. or condensate. b) High Temperature Creep. the tube steel will exhibit a higher creep rate and will fail earlier than expected. 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. b. If the temperature and stresses exceed design selection values.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS The significant subcategories of stress-rupture failure mechanisms are: a) Short-Term Overheating. c) Blockage or lining of boiler gas passage. Residual Life Assessment study of HRSG Page No. debris. d) Operation of a tube material at higher than allowable temperature. b) Loss of coolant circulation or low water level. If temperature and stress exceed design selection values. because the edge of the material is reduced at higher temperatures. Theses abnormal conditions are created by the following circumstances: a) Internal restriction of tube coolant flow by scale. Just prior to a HPHT outlet header. Predominant location for creep failure: a.  High Temperature Creep: - Boiler tube failures can result from high temperature creep of the HT super heater . F136/RLA/KRIBHCO/BLR1/07/2017 . These abnormal conditions are created by following circumstances: a) Internal blockage of the tube. Such failures are often characterized as having knife-edge fractured surfaces. or accumulation on several period of excessive overheating. High temperature creep failures some times are called 'long term' or extended overheating failures. Wall thinning and local bulging precede the actual fracture. 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. Metal degradation and permanent deformation will occur with time depending on actual temperature and stress levels. where the tubing and steam temperature are the highest. b) Reduction of heat transfer capability due to internal (steam-side) surface oxide scales or chemical deposits. c) Loss of coolant due to an upstream tube failure. 13 Report No.

hydrogen damage leads to a degradation of material properties at the operating temperature. Boiler tube failure can also result from high temperature creep at or adjacent to supports or attachment welded to HT super heater tubes. methane is unable to escape. Hydrogen damage is basically a decarburization reaction. which in turn causes local under deposit boiling and concentration of boiler water chemical. Reaction can be written as. In contrast to hydrogen embrittlement. If the cracks occur internally i. Prevention of high temperature creep failure involves keeping tube metal stress and temperature within the capabilities of tube material.e. 2H2+C→CH4 Where the carbon is in the form of carbides. This leads to diminished cooling water flow in contact with the tube. Water Side Corrosion: - Boiler-tube failure due to corrosion can result from prolonged accumulation of water in the header & tubes. and link up to form fissures and cracks. High temperature creep usually results in a longitudinal fractured in the heated side of the tube. coupled with a boiler water low P H excursion. b. This also may occur during extended out of service periods such as outages and storage . forms bubbles and leads to permanent internal damage. Restraints to uniform tube expansion. Differences in thermal expansion properties.  Caustic attack: These occur when there is excessive deposition on ID tube surfaces. Residual Life Assessment study of HRSG Page No.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS e) Increase in stress due to wall thinning. Prevention of the high temperature creep failure involves keeping the tube metal stress and temperature with in the capability of the tube material. F136/RLA/KRIBHCO/BLR1/07/2017 . grow under methane pressure. a. Hydrogen damage is most commonly associated with excessive deposition on ID tube surfaces. The finned attachment also can transfer more heat to the tube and result in higher metal temperature . which degrades toughness at low temperature and imposes restriction on start up and shut down procedures.  Pitting: Oxygen pitting occurs with the presence of excessive oxygen in boiler water. 14 Report No. particularly with salt water cooling medium and leads to acidic (low PH) contaminants that can be concentrated in the deposit. Water chemistry is upset. It can occur during operation as a result of in leakage of air at pumps or failure in operation of preboiler water treatment equipment. such as what can occur from condenser leaks. B. if proper procedures are not followed in lay up.  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.

C.0 APPROACH FOR RLA STUDY Each particular life extension project demands a dedicated study program. B Identification of problem areas and deficiencies in the boiler by walk though survey and interaction with the plants operating personnel. 2. b) Failure of weld at crucial and multiple locations may constitute the end of life header. mechanical damage of tube during installation & overhauling . Mechanical fatigue associated with external applied stresses. it is important from a life assessment point of view for the following reason. alignment of drums & headers to ensure proper assembly of tubes. C Creep life spent is one of the major criteria governing the suitability for further service of high temperature and highly stressed Residual Life Assessment study of HRSG Page No. Creep at weldments and thermal fatigue in header body ligament has emerged as principal damage mechanism. F136/RLA/KRIBHCO/BLR1/07/2017 . they can provide an index of creep damage and remaining life in the base metal. Tubes should be free to expand during operation to avoid any buckling. a) The need for frequent weld repair may prove uneconomical and justify retirement of headers. Header Damage Mechanisms A header is essential a pipe to which tubes are welded. may be associated with vibration due to flue gas & uneven expansion of component. D. comprehensive range of analytical. The underlying methodology and procedure adopted by EEPL is based on the approach of selective. spaced either axially or circumferentially. Initial sign of creep related stress often appears at weld. poor welding of joints. 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. These are subsequently investigated in order to recommend the remedial measures required to ensure maximum future plant availability. Lack of quality control Lack of quality control comprises of feed water chemistry. depending upon the details of the plant involved and the specific requirements of the owner of the plant. Fatigue Fatigue is the result of cyclical stresses in the component.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS  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. a) Because of weld failure in the body. The spacing between tubes is known as ligament. It occurs due to combination of high tensile stresses & corrosive fluids are present. 15 Report No. 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.

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.e. F136/RLA/KRIBHCO/BLR1/07/2017 . Micro cracks observed 4. 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. Similarly if isolated creep pores and chains are seen the inspection is necessary after 5 years. According to Neubauer if micro-figures are noticed in microstructures / replica an immediate replacement is desirable. linked cavities (micro cracks). 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. undamaged. Isolated cavities 2. A graph showing creep life assessment based on cavity classification is given below: 1. isolated cavities oriented cavities. 16 Report No. showing that operational cracks in these components are generally preceded by microscopic grain boundaries cracks and cavitations. If grain boundary micro-cracks are observed a repair or replacement within 6 months. The approach in determining the remnant life of creep affected components on the basis of microstructure examination is fairly revealing and widely accepted. but only spheroidized carbides are observed then creep damage is considered as less and the next inspection is needed after about 5 years.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS components such as those present in high temperature boiler components. Oriented cavities 3. Macro cracks Standard Life Estimation Replica (Source: Standard Metallurgy Book) They characterized cavity evolution in steel at five stages i. and macro Residual Life Assessment study of HRSG Page No.

2 The Remaining Life Assessment is performed for components. consisting of oriented cavities.1 In general approach adopted by EEPL is in line with relevant sections of IBR. repair or replacement would be needed within six months. After the comprehensive visual plant inspection by a team of specialist. the NDT inspection schedule was developed for boiler. For Class – 1 consisting of isolated cavities Re inspection within 5 years would be required. oxide scale measurement . Ultrasonic flaw detection. F136/RLA/KRIBHCO/BLR1/07/2017 . EEPL engineers. 3. 17 Report No. which are operating at or above 450° C. which can be co-related with time. etc. 3. They also formulated the recommendations corresponding to the different stages of cavitations. Study of Pressure part carried out by NDT inspection as Visual inspection. parent metal inspection.12 Level -II 1 Isolated cavities 0.00 D.84 (micro cracks) Level -V 4 Macro cracks 1. such as replication enables assessment of accumulated damage and consequently the remaining life.64 Level -IV 3 Limited cavities 0. Fibroscopy .54-0. 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. chemical analysis of tubes & estimate the remaining life of boiler. 3.3 Some important components of Boiler such as Economizer HP & LP Drum. since they undergo such changes in properties.46 Level -III 2 Oriented cavities 0. which are not operating in creep zone. For Class-2 damage. For Class-3 damage. Magnetic Particle test. The types of tests were planned in consultation with the client and meeting the requirements. are also examined for their present condition.0 METHODOLOGY ADOPTED 3. immediate repair would be required.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS cracks. Dye Penetrant Test. Assessment is based on finding Residual Life Assessment study of HRSG Page No. dimension measurement. Expended life fraction of steels. For undamaged no remedial action would be required. The NDT examination was carried out by qualified / certified personnel. Non- destructive tests. For Class-4 damage. hardness test & mechanical strength . re-inspection within 1½ to 3 years would be required.

Identification of Critical Components: - Critical components are those which are subjected to high temperature / stress and those which have chronic failure history. then component residual life can be assessed. 18 Report No. Identification of critical components.4 Extensive in situ metallography was carried out also Replicas were taken to examine microstructure of various critical components. c) Degree of damage required causing failure. high pressure piping is subjected to piping stress analysis to identify critical areas for NDT. IV. III. II. I. b) Rate of damage accumulation. If an estimate of current damage. Before describing the various phases involved in analytical estimation of residual life of Power Plant components. Crack growth analysis. performed at locations decided on basis of visual inspection. dimensions and clearances of the components are obtained from the production / Residual Life Assessment study of HRSG Page No. A brief outline of the procedure that is adopted at each one of these steps is furnished in the following sections.0(c) above. These steps provide a systematic approach to the solution and are as follows: I. Microstructure changes are most important assessment technique for high temperature components. Stress computations. F136/RLA/KRIBHCO/BLR1/07/2017 .ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS of nondestructive tests. warm start and cold starts. For example. Data Collection for Damage Computations: - The basic data required for damage computations are: - a. To make these assessments. such as hot start. Plant Operational Data: - This includes number of hours of steady operations and number of various start ups. Damage computations. 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). operating history and failures experienced in past. it is also noted down with amplitudes and time duration. the general methodology and guide lines outlined in EPRI documents have been followed. V. II. 3. If the load changes are from past history. b. Geometrical Data of Components: - The relevant geometrical parameters such as thickness. Data collection for damage computations. These norms are developed by Nuebauer and Wedel have now become industry standard as per 2. 1. 2. the entire procedure may be divided in to a few major steps. along with a rule for damage accumulation and failure criterion is known.

F136/RLA/KRIBHCO/BLR1/07/2017 . c. shut down and load changes operations. 19 Report No.This task is essential for the creep fatigue and crack growth analysis of critical components. Stress Computation for Fatigue. Stress Computation for Creep. IV. b) Cumulative damage of critical components that are subjected to steady state and transient stress can be estimated from knowledge of past usage. Total cumulative damage. It is the experience of the past which indicate that the end of predicted creep rupture life as per damage rule. Stress Computations: . ultimate strength are collected. Similarly the stress or strain range computed to derive the number of cycles to failure / crack initiation (Nf). II. yield strength. Thus the damage due to creep and fatigue of a critical component is obtained from which the residual life may be evaluated. properties at desired operating parameters are derived from data collected. 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.+ ∑ ------ Tf Nf Where ti and ni are actual time and cycles. suitable assumptions are made by considering equivalent material and using parametric relations. Dt is defined as the linear sum of damage due to creep and low cycle fatigue: Dt = Dc + Df ti ni Dt = ∑ -----. a. 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. operating stresses and material properties. poisson’s ratio. c) Stresses computed to obtain the creep rupture time (Tf) in hours for the material used. Material Property Data of the Components: - The data required for stress and strain computations such as modulus of elasticity.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS fabrications drawing which are essential for the stress / strain computations. Using certain parametric relations (for example. In case such data are not available for the material under consideration and specifically over a range of desired operating parameters. 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. a. 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. Larson-Miller Parameter for creep rupture time) most suitable for such materials. a crack will initiate at the critical Residual Life Assessment study of HRSG Page No. datas are derived from table or curves available in the literature / materials handbooks.

creep-fatigue) V. creep. casing of turbines.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS location. 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. 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. 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.Collect data on crack size (length-a). F136/RLA/KRIBHCO/BLR1/07/2017 . 20 Report No.. In this case. Crack-Growth Analysis-Procedure Stepwise procedure for remaining life estimates using crack growth analysis is furnished below: a. In such cases. Valve bodies. e) In this. Microstructure based on ND Metallography reveals that the component has reached a stage to contain link up of creep cavities or micro-cracks. Find critical crack length using ac = [----. f) Crack growth analysis is applicable under following conditions: i. ii. 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). b. iv. Q Klc c. Single large crack is present (clustering of proximate micro cracks can be done to simulate their effects through a single crack). location and orientation from NDE (if available) or data may be assumed as indicative above.21Л σ d. iii. Crack growth rate data is available for the prevailing damage mechanism (Viz.+ ------]2 1. and creep rupture criterion based on damage calculations would not sufficient. substantial portion of the life of the component is exposed is spent in crack propagation. Set a factor of safety (fs) on ac and obtain a working limit a r: ar = ac /fs. fatigue. The corresponding stress (Л) evaluated is the principal (maximum) tensile stress normal to direction of crack opening.Find shape factor Q for the crack geometry and fracture toughness Klc for component material. Residual Life Assessment study of HRSG Page No. propagate and eventually cause failure. drums and high energy piping are examples of stationary components which fall under component category for crack growth analysis.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). steam chests.

e. F136/RLA/KRIBHCO/BLR1/07/2017 . say from a 1 to a2 to a3 and so on. photographs. af. along with additional defects. 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. dust deposit etc. Disholoration.0 TEST CONDUCTED: - 5.. is performed for residual life. new set of calculations on the basis outlined above with latest data as inputs. creep and combined creep-fatigue growth rates viz.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS e. The corresponding no. These factors give clue to the internal material and stress status of the components.2 . f. Knowing da/dN and da/dt and (a1-a). During the health assessment of Boiler components. of cycles/time duration is determined for each such step and summed up until value a f is attained. Records consist of description of visual observations often aided by sketches. if any. erosion. otherwise perform crack growth analysis based on data for material on fatigue. 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. components should be first visually inspected to look for the damage. of cycles) obtained from calculations. Method is used for detection of surface breaking cracks or Dishontinuities of non-porous solid material. the no. Criteria for material to be rejected. After the latest inspection data is obtained on the locations of defects identified earlier. scaling. vital measurements. corrosion.. and da/dt respectively. 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).Visual Examination: - This is the most common and first inspection technique done by trained personnel. if a is greater than or equal to af. particularly for non-magnetic materials. Residual Life thus computed is to be sub-divided into practical inspection intervals. The total life left is decided by the sum of total hours (cycles are converted to hours from cycle duration and no. These computations are repeated until the crack length – a attains the terminal value i. The inspection is sometimes aided by magnifying glass.Dye-Penetrant Test. This process is repeated for future inspection. Residual Life Assessment study of HRSG Page No. 21 Report No. Based on this revised estimate new inspection intervals are recommended. 5.1 . This is perhaps one of the most widely used methods of non-destructive testing. da/dN. 5.

Drum.Ultrasonic Thickness Measurement (UT-T):- UT thickness measurements are made on tubes and headers etc.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS The method depends on the capillary action of a liquid. were thoroughly cleaned and dimensions measured to observe the extent of deformation. Due to the ability of this test being performed “In-Situ”. 6. 5. chemical composition or configuration. to know the remaining thickness after erosion and corrosion. The internal surface was observed for pits.1 The calculations were carried out as per IBR regulation requirements. etc. laminations. 5. Valves etc.1 Tube samples from critical zones are removed for detailed examination and analysis in laboratory.3 . 7. 5.6 – Fibroscopy examination Fibroscopic inspection was conducted to know the internal surfaces condition of different critical headers. 5.0 CALCULATIONS DONE TO ARRIVE AT REMNANT LIFE 7. such as Headers. to determine possible creep damage. it is a very important NDT technique to use for component damage assessment and determination of remaining life. It allows detection of surface cracks.Dimensional Measurement:- The components liable for deformation / bulging due to wear creep namely Headers & tubes etc. The following methodology has been considered in the calculations Remnant life has been worked out on the basis of Residual Life Assessment study of HRSG Page No. which enters into cavities in the surface of an otherwise solid piece of material. tubes. lap and porosity in the surface of all kinds of material regardless of size.In-Situ Metallography:- In-Situ Metallography is a NDE technique that is used on high temperature components operating in creep range. tubes. The component to be evaluated is prepared for examination by grinding. 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. F136/RLA/KRIBHCO/BLR1/07/2017 .0 LABORATORY TEST ON TUBE SAMPLES 6. polishing and etching. corrosion or cracks.5 . 22 Report No.4 . For examination at higher magnification the microstructure of the parent metal is recorded and examination in the laboratory on acetate replica tape. The locations are shown in sketch and surface conditions are shown in photographs.

c) Degradation because of oxide scale formation d) LMP method to estimate Remaining life Minimum measured thickness has been considered for calculation of maximum.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS a) Reduction of thickness b) Micro Structure degradation & Diffusional analysis of microstructure. permissible working pressure. Residual Life Assessment study of HRSG Page No. 23 Report No. F136/RLA/KRIBHCO/BLR1/07/2017 .

ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS 7. (c)Estimation of Remaining life by in situ oxide scale measurement: Residual Life Assessment study of HRSG Page No. 87.4 (c) Formula: trem = (1/x – 1) x texp.000 hours. C = 0.5 or Sc whichever is lower for temperature above 454⁰c t = Nominal wall thickness after negative thickness tolerance adjustment.5 for temperature less than 454⁰c Sr/1. F136/RLA/KRIBHCO/BLR1/07/2017 .00.2 Assessment of structural integrity of tubes has been assessed as below.000 hours and in no case more than 1.75 mm for WP upto and including 70kg/cm2.33 times the lowest stress produced in 1. Minimum required thickness Equation 87 is used for finding minimum thickness required to support the design working pressure for permissible stress at working pressure.00. Formula: T min = [(WP) (D+C) + 2FC] / (2F+WP) T min = minimum wall thickness required.000 hours.5 or Sc or Et/1.( 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. For Max permissible working pressure for tubes as per IBR 338 Eqn. (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. Et = Yield point strength at room temp. D = Outer Diameter of tube. Sc = Average stress at working temperature of metal to produce elongation of 1% creep in 1. Ref graph & table 2.7 or Sr/1. = 0 for WP upto exceeding 70kg/cm2. Sr = Average stress at working temperature & working metal to produce rupture in 1. 24 Report No. trem = Remaining life texp = Expended operated life texp/tr = Life fraction expended = x(based on microstructure degradation level) tr = Rupture life. Formula: WP = 2F (t-C) / (D-t + C) WP = Design working pressure in kg/cm2 Ts = Minimum tensile strength at room temperature.00.

22) / (2t x1000) (ksi . T®(13. to3 . T2®.---- P: Larson Miller Parameter obtained from LMP Vs Hoop stress curve 4. to2 . X2 .No.e to1 . inch) LMP can be obtained from nominal stress versus LMP creep curves of the materials. Values taken from nearest material composition.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS  1 mils = 25. tr2 .--- 5.e T1® .e tr1 . Residual Life Assessment study of HRSG Page No. 25 Report No.4 microns  K = oxide scale growth constant Formulae used for data validation: 1. 3. X3 .kilo pounds per sq. Formula: LMP = T x 10-3 x [Log (tr) + 20] T = Temperature in 0 Rankine = (0F + 460) tr = Rupture life in hours.--- tr: : Rupture time in each time interval i.--- P : Larson Miller Parameter obtained from oxide scale thickness in mills Vs LMP Curve 2. Total running hours till date / t r =Life fraction=X( expented life fraction in each interval of time i.e X1 . {(1-a) /a} *life expended =Remaining life 6. in Rankine to : Operating hour in time interval i. T3®.1 for each time interval i. F136/RLA/KRIBHCO/BLR1/07/2017 .62+log to)=P T® : temp. T® (20+log tr)= P (Larson Miller Parameter ) T®: temperature in rankine as obtained in S. WP(D-T)/2T=Hoop Stress WP : working pressure in kg/cm² D: Diameter in mm. LMP = Larsen miller parameter Nominal stress (ksi) = (WP x D x 14. 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. tr3 . T: Thickness of tube in mm.

ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS Remaining life = tr . 26 Report No. F136/RLA/KRIBHCO/BLR1/07/2017 .operating life Residual Life Assessment study of HRSG Page No.

391A.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS 8. Residual Life Assessment study of HRSG Page No.0 NDT PROCEDURES Applicable codes and standard and Procedure followed for NDT A PROCEDURE FOR VISUAL INSPECTION 1. pressure vessels and piping. 6. 27 Report No.2 SNT-TC-1Aof ASNT 3. F136/RLA/KRIBHCO/BLR1/07/2017 .1 Minimum light intensity at examination surface shall be 500 Lux.1 ASME B & P V Code: Section: V. 1 This procedure is applicable for Visual Inspection of internal and external surfaces of equipments.0 Scope: 1 .0 Inspection Aid: 4.0 Purpose: 2.0 Reference Documents: 3.1 Visual Inspect ion shall be performed to check the surface condition and any deterioration during service. 6. area shall be ground smooth and thickness measurement shall be performed for assessing the remaining thickness and acceptance.(a) (b).2 In case of deep pitting/corrosion.0 Lighting: 5. Any abnormality observed shall be investigated and reported.1 Examination shall be conducted thoroughly on all areas. 2. table 1 & 2 4.0 Examination: 6. 5. VIII 3. .1 Magnifying Glass 20X magnification shall be used for minute observation on area selected as per surface condition. 3.3 IBR Regulation 391.

3 SNT-TC-1A of ASNT 4. table 1 5.1 Certification of contaminant content for all liquid penetrant materials used on nickel base alloys. F136/RLA/KRIBHCO/BLR1/07/2017 .1 ASME B&PV Code: Section: V. 6.1 Following brand of Magnaflux make PT materials shall be used: Penetrant : SKL-SP Cleaner : SKC-1 Developer : SKD-S2 8.0 PT Materials: 7.1 Weld Joints: Weld and minimum 25 mm area on both sides of the weld from weld edge shall be tested. 3.1 Solvent removable visible dye technique shall be utilized.0 Scope: 1.1 Liquid penetrant testing shall be performed as per this procedure. 391A.1 Liquid Penetrant Examination shall be performed to detect Discontinuities open to surface.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS B.0 Control of Contaminants: 8.0 Technique: 3.4 IBR Regulation 391. PROCEDURE FOR LIQUID PENETRANT TESTING 1.1 This procedure is applicable for Liquid Penetrant Examination of weld joints and heat affected area and components. austenitic stainless steels and titanium shall be obtained. Residual Life Assessment study of HRSG Page No. 2.0 Examination Coverage: 6. 7. VIII 4. Only parameters and materials described in this procedure shall be utilized. information and requirements for effective performance of the test. 4.(a) (b). a revised procedure shall be required. In case of any change. It describes various processes.0 Procedure Requirements: 5. 28 Report No.2 ASTM Standard: E-165 & E-1220 4.0 Purpose: 2.0 Reference Documents: 4.

0 Standard Temperatures: 10. Cleaning shall be conducted by buffing. is prohibited. 9. Chlorine and Fluorine content shall not exceed 1% by weight. care shall be taken to avoid the excess use of solvent.2 These certificates shall include manufacturer's batch number and test results in accordance with 8.0 Surface Preparation: 9. grease.1 After dwell time. 10.3 Excess Penetrant Removal: 11. 9. following the application of penetrant and prior to developing.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. The remaining traces shall be removed by lightly wiping the surface with lint free cloth moistened with solvent.1 The surface to be tested shall be free from dust.4 below.4 Drying of the surfaces to be examined shall be accomplished by normal evaporation.0 Examination: 11. Flushing the surface with solvent. test surface shall be wiped with lint free cloth and cleaner. F136/RLA/KRIBHCO/BLR1/07/2017 .2 Penetrant Time: 11.2 The test surface shall be free from irregularities that could mask the indications due to Discontinuities.2. 9.1.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS 8. 9.3.1 Penetrant Application: 11.1 Penetrant shall be allowed to remain over test surface for at least 10 minutes (dwell time) 11.1 Penetrant shall be applied over examination surface by brushing 11.3 After cleaning. 11. Repeating the operation until most traces of penetrant have been removed. To minimize removal of penetrant from Discontinuities.3 When examining nickel base alloys.4 Drying After Excess Penetrant Removal: Residual Life Assessment study of HRSG Page No.3 & 8. 8. 8. 11. scale or any other matter that could interfere with the testing. 29 Report No. the excess penetrant shall be removed by wiping with a lint free cloth. Sulphur content shall not exceed 1% of the residue by weight.4 When examining Austenitic Stainless Steel or Titanium.

which have any dimension greater than 1. 12. shall be considered as relevant. 11.3 Mirror/Magnifying Len may be used to facilitate the inspection.4.0 Acceptance Criteria: Residual Life Assessment study of HRSG Page No.5. Only indications. 12.4 Developing time for final interpretation begins immediately as soon as developer coating is dry.1 After application of developer. 12. 14.0 Interpretation: 13.6 Developer Application: 11. 14.6.1 Final interpretation shall be made after 10 to 60 minutes.0 Evaluation: 14.1 The size of the indication is the basis for acceptance evaluation. 30 Report No. F136/RLA/KRIBHCO/BLR1/07/2017 .2 A linear indication is one having a length greater than 3 times the width. 11.5 Developing: 11. 12.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS 11.6 mm.5 The test surface shall be kept under observation for 10 minutes 13.1 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.0 Inspection: 12. 15.1 Non-aqueous developer shall be applied to dry surface.6.1 The surface shall be dried by normal evaporation. the test surface shall be closely observed for appearance of any indication.2 A thin and uniform coating of Developer shall be applied over examination surface by spraying.2 Inspection shall be performed under white light. 14. 12. 11. The minimum light intensity at the test surface shall be 1000 lux.3 A rounded indication is one of circular or elliptical shape with a length equal to or less than three times its width.

ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS (a) Imperfections producing the indications shall be evaluated as per design code of vessel. Residual Life Assessment study of HRSG Page No. 31 Report No. F136/RLA/KRIBHCO/BLR1/07/2017 .

0 Purpose: 2.0 Scope: 1 . 6. F136/RLA/KRIBHCO/BLR1/07/2017 .4 IBR Regulation 391. 32 Report No.1 Ultrasonic Thickness Gauging shall be performed for assessing remaining thickness. table 1 & 2 Surface Preparation: The location for thickness measurement shall be free from dust.3 ASTM Standard SA 797 4.The thickness measurement shall be performed at ambient surface temperature.2 SNT-TC-1A of ASNT 4. 1 This procedure is applicable for Ultrasonic Thickness Gauging of vessels and piping. scale or any other matter that could interfere with the effective coupling and the thickness reading.1 Digital Read out Equipment operating on Pulse Echo Technique shall be utilized. 391A. Reference Documents: 4. 3. 7. VIII 4.(a) (b).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.1 ASME B & PV Code: Section: V. 2.0 THICKNESS GAUGING LOCATIONS: Thickness locations shall be shown in sketch or described in thickness report. Residual Life Assessment study of HRSG Page No.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS C PROCEDURE FOR ULTRASONIC THICKNESS GAUGING: 1.0 Technique: 3.

6.1 Select the locations for metallography 6.0 STUDY: 7.1 Metallography is performed to obtain Metallurgical structure of material to study the degradation level.2 Perform preliminary cleaning for removal of scale. 6.1 Sampled location is cleaned. Image is stored as soft copy and transferred to PC for study and interpretation. 7. 4. 33 Report No. Residual Life Assessment study of HRSG Page No. Degradation at grain level can be viewed to study the aging effect of component in service.7 Chemical etching after cleaning the surface.3 Grind the surface to make it smooth.10 Replica will be studied through an optical microstructure in the laboratory. 5. rust oil etc. piping & weld surface.0 PURPOSE: 2. 6. 6.0 PRINCIPLE: 3.(a) (b). 6.5 Perform polishing with polish paper and polishing liquid.8 Inspect the surface for grain structure and record the image. table 1 & 2 5. 6.1 Study the microstructure recorded and the image with reference structures for study of degradation. 3.1 This procedure is applicable for in-situ metallography of Tubes. Quality of polish and microstructure is observed through portable microscope.1. 6.0 PROCEDURE: 6. grind and polished to the extent that micro structure is visible. 6. if pitting is present.1.1.1 IBR Regulation 391.6 Clean and wash the surface.0 SCOPE: 1.0 CAPABILITIES & LIMITATION: 4.1.0 REFERENCE DOCUMENTS: 5.4 Perform buffing of the spot using different grades of buffing wheels.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS D Procedure for In-Situ Metallography / Replication 1. F136/RLA/KRIBHCO/BLR1/07/2017 .9 Take Replication on gold plated & / or Replication strip. 391A.1 This provides information about internal condition of material.2 ASTM Standard for metallography. 2. 6.

in situ oxide scale thickness measurement and destructive test results of tube samples. Nuebauer and Wedel method of interpretation of microstructural damage and prediction of remnant life based on Microstructure degradation levels as furnished in the report. Oxide thickness inspection 4. Destructive test results. F136/RLA/KRIBHCO/BLR1/07/2017 . reduction in thickness. 15 and 16. 34 Report No.  The expended life of each of these categories has been evaluated as per the criteria mentioned on page 14. Reduction of thickness. 3. 2.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS REMAINING LIFE OF BOILER PRESSURE PARTS Remaining Life of Boiler Pressure Parts has been calculated by considering the following 1. Residual Life Assessment study of HRSG Page No. 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.

Component Expended Minimum Remaining Life fraction Life in Hours (X) 1. Super Heater Header 0.46 117391 2.46 117391 7. No. Economiser tube 0.46 117391 6. 35 Report No. De Super heater 0.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS 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.46 117391 Residual Life Assessment study of HRSG Page No. Economiser header 0.46 117391 4.46 117391 5. Main Steam line 0. DRUM 0.46 117391 8. SH header tube 0. Feed water line 0. F136/RLA/KRIBHCO/BLR1/07/2017 .46 117391 3.

Sr. SH header Run Nil Nil Nil Nil Nil next RLA will tube be done 5. No. ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS 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. F136/RLA/KRIBHCO/BLR1/07/2017 . Economiser Run Nil Nil Nil Nil Nil next RLA will header be done 7. 36 Report No. UP. The following are component wise recommendations. De Super Run Nil Nil Nil Nil Nil next RLA will heater be done 3. 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. DRUM Run Nil Nil Nil Nil Nil next RLA will be done 2. Replacement : Change the equipment by new equipment Residual Life Assessment study of HRSG Page No. tion 1st 2nd 3rd 4th 5th 6th year year year year year year 1.5318) of Kribhco Shyam Fertilizers. Main Steam Run Nil Nil Nil Nil Nil next RLA will line be done 6. Component Recommenda Six Year Action Plan No. Economiser Run Nil Nil Nil Nil Nil next RLA will tube be done 4.

still it is recommended that RLA study be carried out after five years. Residual Life Assessment study of HRSG Page No.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. No. Even though the residual life is coming out to be more than ten years. UP. It is concluded that the HRSG # 1 (Regn. 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. 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. F136/RLA/KRIBHCO/BLR1/07/2017 .ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS CONCLUSION Based on the results of tests carried out during the course of RLA study. 37 Report No.

0 60.1 .0 2 60. Dimensional measurement: BOILAR DRUM (DISHEND) THICK(LHS) THICK(RHS) 1 61. tapping point joints & stub joints. & Hardness 5 Internal  Drum deposit analysis indicates chemical deposit composition within limit.6 2 78.9 1750.59. No significant defect observed.9 60. 4 In-situ  As per Wedel-Neubauer classification the Metallography component is in between level I & level II. 38 Report No. F136/RLA/KRIBHCO/BLR1/07/2017 .5 62.59.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS SUMMARY OF TEST REPORTOF DRUM Sl.9 ECO O/L TO DRUM LINK PIPE-1 THICK OD 1 13. analysis 6 ID &  ID & Thickness measured at different locations and Thickness no major deviation recorded.9 1750.1 170.  Pitting observed at the inner surface of weld & parent metal.0 5 77.2 4 74. 2 DPT  Dye penetrant test carried out on circumferential.1 1750.3 .5 7 76.2 3 61.0 mm. Inspection  Thin layer of corrosion observed on outer surface and inner surface of HP drum. long seam weld. 3 UT  Circumferential & long seam weld joints were checked by ultrasonic method and no remarkable indication observed.3 4 60.2 61.2 Residual Life Assessment study of HRSG Page No. Test Observations No.1 2 14. Pitting depth found up to 1.9 170.5 6 78.0 BOILAR DRUM (SHELL) THICK THICK ID 1 77.3 8 78. 1 Visual  Drum visually inspected both inside & outside.4 1750.0 3 77.

142. Deposit analysis. 155. 39 Report No. 110. Hardness measurement and dimensional measurement. drum will work efficiently for more than 10 years. F136/RLA/KRIBHCO/BLR1/07/2017 . However the re- inspection of the component is recommended as per IBR 391 A.0 170. 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’ .0 4 14. 145 HAZ: 140.1 2 13.5 170.1 ECO O/L TO DRUM LINK PIPE-2 THICK OD 1 14. 114 Recommendation: Based on visual inspection.7 170.0 HARDNESS TEST REPORT STEAM DRUM: WELD M: 150. Ultrasonic test. Residual Life Assessment study of HRSG Page No. Drum was found in satisfactory condition. Residual Life: If further operating condition continues as in the past.2 4 14.1 3 14.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS 3 13. In-situ Metallography. Dye Penetrant test.0 170.7 170. 143 PM: 112. .2 170.

thin layer of corrosion and the assessment after observed on the outer surface of analysis .Shahjahanpur Used Report No. the drum is fit the drum.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS TEST REPORT BOILER & AUXILIARIES Visual Inspection Report Equipment Magnifying Glass Customer KSFL. VI-01 Date of 05/7/17 TO 08/7/17 Inspection SL Compone Observation Recommendation No. No other significant for continued operation defect/ discontinuity was Since the pitting depth is observed. nt 1 Drum Drum visually inspected externally Based on the observation & internally. within the permissible limit hence only proper insulation of outer surface of drum is sufficient. 40 Report No. Residual Life Assessment study of HRSG Page No. F136/RLA/KRIBHCO/BLR1/07/2017 .

ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS

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

Residual Life Assessment study of HRSG Page No. 41
Report No. F136/RLA/KRIBHCO/BLR1/07/2017

ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS

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

Residual Life Assessment study of HRSG Page No. 42
Report No. F136/RLA/KRIBHCO/BLR1/07/2017

ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS

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)

Residual Life Assessment study of HRSG Page No. 43
Report No. F136/RLA/KRIBHCO/BLR1/07/2017

Polishing machine. 44 Report No. Etchant.Shahjahanpur Used Report No. RPL-01 Date of Inspection 05/7/17 TO 08/7/17 Material used Cleaner. As per general internationally accepted classification of creep cavitation. Metal foil. F136/RLA/KRIBHCO/BLR1/07/2017 . i.38. No microstructural degradation is observed.e expended life fraction is 0. Residual Life Assessment study of HRSG Page No. Recommendation This microstructure does not show any metal degradation.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS Equipment Replica KIT Customer KSFL. Microscope Component Drum Location RHS – Parent Metal 200X Observation Microstructure show predominent structure of pearlite & farrite. this microstructure matches nearly damage class ‘1’ which corresponds to no creep cavitation. Life Fraction As per Wedel–Neubauer classification the component is in between level I & level II.

Metal foil. 45 Report No. F136/RLA/KRIBHCO/BLR1/07/2017 .e expended life fraction is 0. Recommendation This microstructure does not show any metal degradation. Polishing machine.38. No microstructural degradation is observed.Shahjahanpur Used Glass Report No. As per general internationally accepted classification of creep cavitation. Residual Life Assessment study of HRSG Page No. Microscope Component Drum Location RHS – Parent Metal 200X Observation Microstructure show predominent structure of pearlite & farrite.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS In Situ Metallography Evaluation Report ( RPL) Equipment Magnifying Customer KSFL. i. Life Fraction As per Wedel–Neubauer classification the component is in between level I & level II. RPL-02 Date of Inspection 05/7/17 TO 08/7/17 Material used Cleaner. this microstructure matches nearly damage class ‘1’ which corresponds to no creep cavitation. Etchant.

In-situ Metallography.8 3 25.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS SUMMARY OF TEST REPORT OF MAIN STEAM LINE Sl. 46 Report No.9 4 24. Ultrasonic test.Main Steam Line will work efficiently for more than 10 years. No significant defect observed.6 219. 4 In-situ  As per Wedel-Neubauer classification the Metallography component is in between level I & level II. & Hardness 6 OD &  OD & Thickness measured at different locations and Thickness no major deviation recorded. Dye Penetrant test. Dimensional measurement: MAIN STEEM LINE THICK THICK(BEND) OD 1 25. 3 UT  Circumferential & long seam weld joints were checked by ultrasonic method and no remarkable indication observed. tapping point joints & stub joints.7 220.162 Recommendation: Based on visual inspection. Test Observations No.7 27.2 219. 2 DPT  Dye penetrant test carried out on circumferential.1 HARDNESS TEST REPORT PM : 142.2 27. F136/RLA/KRIBHCO/BLR1/07/2017 . Inspection  Thin layer of corrosion observed on outer surface and inner surface of Main Steam Line. Main Steam Line was found in satisfactory condition.7 28. Residual Life Assessment study of HRSG Page No.138 WM: 157. Hardness measurement and dimensional measurement. 1 Visual  Main Steam Line visually inspected outside. However the re-inspection of the component is recommended as per IBR 391 A.0 2 25.4 27.9 220.

it is expected that the 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 measurement & microstructure is nearly matching damage class ‘1’ . the Main Line corrosion found.SHAHJAHANPUR Used Report No. VI-04 Date of 05/7/17 TO 08/7/17 Inspection SL Compone Observation Recommendation No. 47 Report No.Thin layer of analysis . F136/RLA/KRIBHCO/BLR1/07/2017 . . Residual Life Assessment study of HRSG Page No. TEST REPORT BOILER & AUXILIARIES Visual Inspection Report Equipment Magnifying Glass Customer KSFL. nt 1 Main Main Steam Line visually Based on the observation Steam inspected In visual inspection and the assessment after Main Steam Line .ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS Residual Life: If further operating condition continues as in the past. No other Steam Line is fit for significant defect/ discontinuity continued operation was observed.

grease oil mix. ce pta ble 04 Stub joint of safety 02 Nos. Equipment Equipment calibration by V1 & V2 Surface As Calibration block Condition Cleane d Tested / As per ASME sec V Accepted Test Parameter Probe Size Freq Range of Machine Setting 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. UT-04 Date of Inspection Equipment and Ultrasonic flaw detector models DG Scan 322 make EEC. ce pta ble Resul Accepted All Defects Noticed Nil t Residual Life Assessment study of HRSG Page No. NO Component Quantity Interpretation Re m ar ks 01 Circumferential 02 Nos. No remarkable indication Ac valve observed.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS Ultrasonic Testing Report (UT) Equipment UT Machine Customer KSFL. No remarkable indication Ac Joints observed.Shahjahanpur Used Report No. 48 Report No. Material Used normal and angle beam probes. F136/RLA/KRIBHCO/BLR1/07/2017 . calibration block V1 & V2.

Component Quantit Interpretation Remarks y 1 Circumferential joints 02 Nos. DPT-04 Date of Inspection 04/07/17 TO 0707/17 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 MAIN STEAM LINE S.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS Dye Penetration Test Report (DPT) Equipment Used DPT kit Customer Report No. 49 Report No. F136/RLA/KRIBHCO/BLR1/07/2017 . No surface defect Acceptable Resul Accepted All Defects Noticed Nil t Residual Life Assessment study of HRSG Page No.NO.

ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS In Situ Metallography Evaluation Report ( RPL) Equipment Magnifying Customer KSFL.38. RPL-06 Date of Inspection 05/07/2017 to 07/07/2017 Material used Cleaner. F136/RLA/KRIBHCO/BLR1/07/2017 . this microstructure matches nearly damage class ‘1’ which corresponds to no creep cavitation. Microscope Component Main steam line WM 200X Observation Microstructure shows columnar ferrite & pearlite/ bainite structure.Shahjahanpur Used Glass Report No. 50 Report No. Life Fraction As per Wedel–Neubauer classification the component is in between level I & level II.e expended life fraction is 0. i. Etchant. Metal foil. Polishing machine. No microstructural degradation is observed. Recommendation This microstructure does not show any metal degradation. As per general internationally accepted classification of creep cavitation. Residual Life Assessment study of HRSG Page No.

Shahjahanpur Used Glass Report No.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS In Situ Metallography Evaluation Report ( RPL) Equipment Magnifying Customer KSFL. this microstructure matches nearly damage class ‘1’ which corresponds to no creep cavitation. Microscope Component Main steam line PM 200X Observation Microstructure shows columnar ferrite & pearlite/ bainite structure. i. Metal foil. As per general internationally accepted classification of creep cavitation. RPL-06 Date of Inspection 05/07/2017 to 07/07/2017 Material used Cleaner.38. Polishing machine. Residual Life Assessment study of HRSG Page No. Recommendation This microstructure does not show any metal degradation. Etchant. Life Fraction As per Wedel–Neubauer classification the component is in between level I & level II. F136/RLA/KRIBHCO/BLR1/07/2017 . 51 Report No. No microstructural degradation is observed.e expended life fraction is 0.

1.Evaporator Header will work efficiently for more than 10 years. Dimensional measurement: EVAPORATOR HEADER THICK OD 1 34.137 Recommendation: Based on visual inspection. Residual Life Assessment study of HRSG Page No. 3.0 N.A 3 34.A 4 35.6 N. 2. However the re-inspection of the component is recommended as per IBR 391 A.A Hardness: 132. Residual Life: If further operating condition continues as in the past. 4. Hardness  Hardness carried out at header. Evaporator Header was found in satisfactory condition. DPT  Dye penetrant test carried out on circumferential seam weld. tapping point joints & stub joints. . Dye Penetrant test.0 N. and dimensional measurement. 52 Report No. F136/RLA/KRIBHCO/BLR1/07/2017 . it is expected that the 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’ .ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS SUMMARY OF TEST REPORTOF EVAPORATOR HEADER(TOP & BOTTOM) Sl.9 N. Visual  HP Evaporator O/L Header visually inspected Inspection outside.A 2 35. Test Observations No. No significant defect observed. OD &  OD & Thickness measured at different locations and Thickness no major deviation recorded.

Shahjahanpur Used Report No. nt 1 Evaporator Evaporator Header visually Based on the observation Header inspected In visual inspection HP and the assessment after Evaporator Header . 53 Report No. operation Residual Life Assessment study of HRSG Page No. F136/RLA/KRIBHCO/BLR1/07/2017 . No other analysis .ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS TEST REPORT BOILER & AUXILIARIES Visual Inspection Report Equipment Magnifying Glass Customer KSFL. VI-06 Date of 05/07/17 to 07/07/17 Inspection SL Compone Observation Recommendation No. the Evaporator significant defect/ discontinuity Header is fit for continued was observed.

ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS Dye Penetration Test Report (DPT) Equipment Used DPT Kit & Customer KSFL.Shahjahanpur Magnifying Glass Report No. 54 Report No.NO. Component Quantit Interpretation Remarks y 1 Stub joints All No surface defect Acceptable Resul Accepted All Defects Noticed Nil t Residual Life Assessment study of HRSG Page No. F136/RLA/KRIBHCO/BLR1/07/2017 . DPT-06 Date of Inspection 05/07/17 to 07/07/17 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 HP Evaporator HEADER S.

calibration block V1 & V2. normal and angle beam probes.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS Ultrasonic Testing Report (UT) Equipment UT Machine Customer KSFL. F136/RLA/KRIBHCO/BLR1/07/2017 . 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. ce pta ble Resul Accepted All Defects Noticed Nil t Residual Life Assessment study of HRSG Page No. 55 Report No.Shahjahanpur Used Report No. Equipment Equipment calibration Surface As Cleaned Calibration by V1 & V2 block Condition Tested / Accepted As per ASME sec V Test Parameter Probe Size Freq Range of Machine Setting 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 HP EVAPORATOR HEADER S. NO Component Quantity Interpretation Re m ar ks 01 Circumferential all No remarkable indication Ac Joints observed. grease oil mix.

1 Visual  HP Evaporator tube visually inspected outside. HP evaporator tubes will work efficiently for more than 10 years. Residual Life Assessment study of HRSG Page No. However the re-inspection of the component is recommended as per IBR 391 A. Test Observations No. it is expected that the evaporator tubes 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’ . F136/RLA/KRIBHCO/BLR1/07/2017 . . vaporator tubes was found in satisfactory condition. Recommendation: Based on visual inspection and dimensional measurement. Residual Life: If further operating condition continues as in the past.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS SUMMARY OF TEST REPORTOF EVAPORATOR TUBE Sl. Inspection 4 OD &  OD & Thickness measured at different locations and Thickness no major deviation recorded. 56 Report No.

No other analysis . F136/RLA/KRIBHCO/BLR1/07/2017 . 57 Report No. the Evaporator significant defect/ discontinuity Tube is fit for continued was observed. VI-07 Date of 05/07/17 to 07/07/17 Inspection SL Compone Observation Recommendation No. operation Residual Life Assessment study of HRSG Page No. nt 1 Evaporator Evaporator Tube visually Based on the observation tubes inspected In visual inspection and the assessment after Evaporator Tube .ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS TEST REPORT BOILER & AUXILIARIES Visual Inspection Report Equipment Magnifying Glass Customer KSFL Used Report No.

4.0 51.8 51.2 3.0 26. 4. 4. 5. 5. 4.9 51. 5.2 22.1 11.8 51.0 51.1 28.3 10. 4. 4.0 51. 4. 5. 4.0 Residual Life Assessment study of HRSG Page No. F136/RLA/KRIBHCO/BLR1/07/2017 .8 51. 4.0 5.1 2.7 51.1 13.7 51.1 51.9 51.0 51. 5. 5. 4. 58 Report No. 4. 5.2 51.9 51. 4. 4.8 51.3 24. 4. 4.2 7.9 51.0 51.0 51.8 51.8 51.2 30.2 27.2 19.9 51.0 4. 4.9 51. 5.0 51. 4.0 17.9 51.2 15.8 51.1 16.0 51.2 12. 5.0 51.3 18.3 21.1 8.9 51. THICK OD 1.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS EVAPORATER-1 COILS SR NO.2 9.1 51.1 29.0 14.9 51.1 20. 5. 5.0 25. 4.3 6.1 23. 5.

5. 5.0 51.1 3.9 51.1 15.6 51.2 8.0 23.2 30.0 51.7 51. 4. F136/RLA/KRIBHCO/BLR1/07/2017 . 4.1 5. 4.7 51.2 19. 4.2 51. 4.8 51.2 4. 4.9 51. 4. 4. 4. 59 Report No. 4.9 51. 4.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS EVAPORATER-2 COILS SR NO. 5.0 2.0 51. 4.9 51.0 51. 4. 5.9 51.0 7.0 51.1 25.9 51.1 13.2 14.7 51.8 51. 4. 4.1 20. 5.1 21.0 51.2 17.1 18.2 26.7 51. 4. THICK OD 1. 4. 4. 5.6 51.0 22.1 51. 4.6 51.0 Residual Life Assessment study of HRSG Page No.2 11.1 10.9 51.8 51. 5.7 51.9 51.1 6. 4.1 29.9 51.1 16. 4. 4.1 27. 5.2 24.0 28.8 51.0 9.1 12.8 51.

7 275. Test Observations No. Inspection  Thin layer of corrosion observed on outer surface and inner surface of De super heater.9 275.132 WM: 157.5 4 23. Hardness measurement and dimensional measurement.7 HARDNESS TEST REPORT PM: 143. De super heater was found in satisfactory condition.9 275.6 275.4 3 24. 4 In-situ  As per Wedel-Neubauer classification the Metallography component is in between level I & level II. Residual Life: If further operating condition continues as in the past. Dye Penetrant test. 3 UT  Circumferential seam weld joints were checked by ultrasonic method and no remarkable indication observed. No significant defect observed. it is expected that the Residual Life Assessment study of HRSG Page No. Ultrasonic test.De super heater will work efficiently for more than 10 years. 2 DPT  Dye penetrant test carried out on circumferential seam weld. Dimensional measurement: De Super heater Header THICK OD 1 24. However the re-inspection of the component is recommended as per IBR 391 A. tapping point joints & stub joints.6 2 24.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS SUMMARY OF TEST REPORTOF DE SUPER HEATER Sl. In-situ Metallography. & Hardness 6 OD &  OD & Thickness measured at different locations and Thickness no major deviation recorded.148. 1 Visual  De super heater visually inspected outside. F136/RLA/KRIBHCO/BLR1/07/2017 .164.162 Recommendation: Based on visual inspection. 60 Report No.

ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS De super heater 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’ . 61 Report No. TEST REPORT BOILER & AUXILIARIES Visual Inspection Report Equipment Magnifying Glass Customer KSFL. the De super found.SHAHJAHANPUR Used Report No. No other significant defect/ heater is fit for continued discontinuity was observed. . F136/RLA/KRIBHCO/BLR1/07/2017 . operation Residual Life Assessment study of HRSG Page No.Thin layer of corrosion analysis . VI-04 Date of 05/07/17 TO 07/07/17 Inspection SL Compone Observation Recommendation 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 .

calibration block V1 & V2. 04 Stub joint of safety 02 Nos. Equipment Equipment calibration Surface As Cleaned Calibration by V1 & V2 block Condition Tested / As per ASME sec V Report No. 62 Report No. NO Component Quantity Interpretation Remarks 01 Circumferential 02 Nos. normal and Material Used angle beam probes. No remarkable indication Acceptable Joints observed. F25/RLA/BRPL/BLR3/08 Accepted Test Parameter Probe Size Freq Range of Machine Setting CRT Technique Dia (mm) MHz mm Pulse Amplitude Suppression /angle db % 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 DE SUPER HEATER S. DPT-04 Date of Inspection 06/07/17 Tested / Accepted As Per ASME Sec V Residual Life Assessment study of HRSG Page No. No remarkable indication Acceptable valve observed. grease oil mix. F136/RLA/KRIBHCO/BLR1/07/2017 . UT-04 Date of 05/07/17 Inspection Equipment and Ultrasonic flaw detector models P X 10 make Parikh Industry. ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS Ultrasonic Testing Report (UT) Equipment UT Machine Cust KSFL Shahjahanpur Used Report No. Resul Accepted All Defects Noticed Nil t Dye Penetration Test Report (DPT) Equipment Used DPT kit Customer Ksfl.shahjahanpur Report No.

Component Quantit Interpretation Remarks y 1 Circumferential joints 02 Nos. ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS 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 DE SUPER HEATER S. 63 Report No. No surface defect Acceptable Resul Accepted All Defects Noticed Nil t Residual Life Assessment study of HRSG Page No. F136/RLA/KRIBHCO/BLR1/07/2017 .NO.

As per general internationally accepted classification of creep cavitation. this microstructure matches nearly damage class ‘1’ which corresponds to no creep cavitation. Life Fraction As per Wedel–Neubauer classification the component is in between level I & level II.e expended life fraction is 0.Shahjahanpur Used Glass Report No. Residual Life Assessment study of HRSG Page No. Microscope Component De super heater WM 200X Observation Microstructure shows columnar ferrite & pearlite/ bainite structure. Etchant. 64 Report No. Polishing machine. i. RPL-06 Date of Inspection 05/07/2017 to 07/07/2017 Material used Cleaner. No microstructural degradation is observed. Recommendation This microstructure does not show any metal degradation. F136/RLA/KRIBHCO/BLR1/07/2017 .38. ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS In Situ Metallography Evaluation Report ( RPL) Equipment Magnifying Customer KSFL. Metal foil.

Microscope Component De super heaterPM 200X Observation Microstructure shows columnar ferrite & pearlite/ bainite structure. RPL-06 Date of Inspection 05/07/2017 to 07/07/2017 Material used Cleaner. this microstructure matches nearly damage class ‘1’ which corresponds to no creep cavitation. i. Life Fraction As per Wedel–Neubauer classification the component is in between level I & level II.e expended life fraction is 0.38. F136/RLA/KRIBHCO/BLR1/07/2017 . Etchant.Shahjahanpur Used Glass Report No. ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS In Situ Metallography Evaluation Report ( RPL) Equipment Magnifying Customer KSFL. Polishing machine. 65 Report No. Recommendation This microstructure does not show any metal degradation. No microstructural degradation is observed. As per general internationally accepted classification of creep cavitation. Metal foil. Residual Life Assessment study of HRSG Page No.

5 170. .9 170. tapping point joints & stub joints. Feed Water line will work efficiently for more than 6 years However the re-inspection of the component is recommended as per IBR 391. Dimensional measurement: FEED WATAR LINE THICK OD 1 14.9 170. F136/RLA/KRIBHCO/BLR1/07/2017 . 3 UT  Circumferential & long seam weld joints were checked by ultrasonic method and no remarkable indication observed.2 3 14. Dye Penetrant test.and dimensional measurement.A. 66 Report No.0 4 15. Feed Water line was found in satisfactory condition. Ultrasonic test.  Thin layer of corrosion observed on outer surface 2 DPT  Dye penetrant test carried out on circumferential.1 Recommendation: Based on visual inspection. long seam weld. Test Observations 1 Visual Inspection  Feed Water line visually inspected outside.3 170.3 2 15. No significant defect observed.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS SUMMARY OF TEST REPORT OF FEED WATER LINE Sl. 6 OD & Thickness  OD & Thickness measured at different locations and no major deviation recorded. No. 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’ . Residual Life Assessment study of HRSG Page No. Residual Life: If further operating condition continues as in the past.

the Feed Water line defect/ discontinuity was observed. 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 . 67 Report No. In visual inspection minor and the assessment after pitting observed. is fit for continued operation Residual Life Assessment study of HRSG Page No.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS TEST REPORT BOILER & AUXILIARIES Visual Inspection Report Equipment Used Magnifying Glass Customer KSFL SHAHJAHANPUR Report No. No other significant analysis. F136/RLA/KRIBHCO/BLR1/07/2017 .

68 Report No. normal and and Material angle beam probes. Accepted Test Parameter Probe Size Freq Range of Machine Setting 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 S.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS Ultrasonic Testing Report (UT) Equipment Ultrasonic flaw detector models P X 10 make Parikh Industry. NO Component Quantity Interpretation Remarks 01 Circumferential 02 Nos. calibration block V1 & V2. F136/RLA/KRIBHCO/BLR1/07/2017 . grease oil mix. Result Accepted All Defects Noticed Nil Residual Life Assessment study of HRSG Page No. Used Equipment Equipment calibration Surface As Cleaned Calibration by V1 & V2 block Condition Tested / As per ASME sec V Report No. No remarkable indication Acceptable Joints observed.

Component Quantit Interpretation Remarks y 1 Circumferential joints 02 Nos. No surface defect Acceptable Result Accepted All Defects Noticed Nil Residual Life Assessment study of HRSG Page No.NO. F136/RLA/KRIBHCO/BLR1/07/2017 .ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS Dye Penetration Test Report (DPT) 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 Feed Water line S. 69 Report No.

Finding/ Observation Remark No. 70 Report No. 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. tested A Feed Water line 2 Circumferential weld seam 2 No recordable Acceptable discontinuity observed Result Accepted All Defects Noticed Nil Residual Life Assessment study of HRSG Page No. F136/RLA/KRIBHCO/BLR1/07/2017 . dust. oil & grease.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS Magnetic Particle Test Report Particular of test Wet fluorescent Magnetic Particle Testing Surface condition Free from loose scale. Surface was clean & dry. paint. Name of components Qty.

Metal foil. As per general internationally accepted classification of creep cavitation. VI-01 Date of Inspection 05/07/2017 to 07/07/2017 Material used Cleaner. i. this microstructure matches nearly damage class ‘1’ which corresponds to no creep cavitation. Recommendation This microstructure does not show any metal degradation. Microscope 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. Etchant.48. Residual Life Assessment study of HRSG Page No.46 to 0. 71 Report No. Polishing machine.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS In Situ Metallography Evaluation Report ( RPL) Equipment MICROSCOPE Customer KSFL SHAHJAHANPUR Used Report No. F136/RLA/KRIBHCO/BLR1/07/2017 . No microstructural degradation is observed.e expended life fraction is 0.

e expended life fraction is 0. Microscope Component Feed Water Line Location Parent Metal 200X Observation Microstructure shows ferrite & pearlite structure. Residual Life Assessment study of HRSG Page No. 72 Report No.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS In Situ Metallography Evaluation Report ( RPL) Equipment Magnifying Glass Customer KSFL SHAHJAHANPUR Used Report No.48. i. No microstructural degradation is observed. Polishing machine. this microstructure matches nearly damage class ‘1’ which corresponds to no creep cavitation. Metal foil. As per general internationally accepted classification of creep cavitation. F136/RLA/KRIBHCO/BLR1/07/2017 . VI-01 Date of Inspection 05/07/2017 to 07/07/2017 Material used Cleaner.46 to 0. Etchant. Recommendation This microstructure does not show any metal degradation. Life Fraction As per Wedel–Neubauer classification the component is in between level I & level II.

13.9 170.2 4 25. SATURATED TUBE Sl. No significant defect observed. 6 OD & Thickness  OD & Thickness measured at different locations and no major deviation recorded.2 12. 14.6 170. 13.3 275. Riser Tube .1 10.1 4. F136/RLA/KRIBHCO/BLR1/07/2017 .3 6.0 275.1 DOWN COMAR-2 THICK OD 1 25. RISER TUBE . Saturated Tube visually inspected outside.7 275. 14.9 170. 14.2 3.0 3 24.0 170.7 170.0 RISER TUBE SR NO.4 170.6 170.1 5.7 170. 13.0 2 24. 13.3 170.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS SUMMARY OF TEST REPORT OF DOWN COMER .1 2 24. 14. 73 Report No. 13. 14.1 13.5 275. No.0 Residual Life Assessment study of HRSG Page No. 14. THICK OD 1. Dimensional measurement: DOWN COMER-1 THICK OD 1 24.0 3 25.6 275.6 275.1 9.5 170.0 11.0 8.0 7.3 170.  Thin layer of corrosion observed on outer surface 2 DPT  Dye penetrant test carried out on stub joints.3 170.3 275.3 4 24. 13.0 2.1 170. 13.9 275. Test Observations 1 Visual Inspection  Down Comer .

Dye Penetrant test. . Feed Water line will work efficiently for more than 6 years However the re- inspection of the component is recommended as per IBR 391. F136/RLA/KRIBHCO/BLR1/07/2017 .9 100. Riser Tube . Residual Life: If further operating condition continues as in the past. it is expected that the Down Comer . Saturated Tube was found in satisfactory condition.A.6 100. .0 100.and dimensional measurement Down Comer .0 4 9.3 2 10.7 100.1 Recommendation: Based on visual inspection. Residual Life Assessment study of HRSG Page No. Riser Tube . 74 Report No.2 3 9. THICK OD 1 9. 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’ .ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS SATURATED TUBE SR NO.

75 Report No. the Down Comer .ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS TEST REPORT BOILER & AUXILIARIES Visual Inspection 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. discontinuity was observed. analysis. Saturated Riser Tube . externally No other significant defect/ and the assessment after Riser Tube . F136/RLA/KRIBHCO/BLR1/07/2017 . Saturated Tube Tube is fit for continued operation Residual Life Assessment study of HRSG Page No. 1 Down Feed Water line visually inspected Based on the observation Comer .

Component Quantit Interpretation Remarks y 1 Stub l joints ALL No surface defect Acceptable Result Accepted All Defects Noticed Nil Residual Life Assessment study of HRSG Page No.NO.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS Dye Penetration Test Report (DPT) 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 Down Comer . Saturated Tube S. F136/RLA/KRIBHCO/BLR1/07/2017 . 76 Report No. Riser Tube .

DPT  Dye penetrant was carried on circumferential weld joints. Dye Penetrant test. No significant surface defect observed.ENERGO ENGINEERING PROJECTS LIMITEDKRIBHCO SHYAM FERTILIZERS ECONOMISER HEADERS (INLET & OUTLET) Sl. tube stub joints. Dimensional measurement: Recommendation: Based on visual inspection. Residual Life Assessment study of HRSG Page No. attachment weld joints etc. F136/RLA/KRIBHCO/BLR1/07/2017 . the components were found in satisfactory condition & suitable for further operation. However. 77 Report No. 1. 3. dimensional measurement. 391 A. 2. Visual  ECONOMISER headers (inlet & outlet) were visually Examination inspected and found in satisfactory condition. Dimensional  Dimensional measurement carried out. Test Observations No. 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. Details measurement measurements have been furnished separately in this chapter.

F136/RLA/KRIBHCO/BLR1/07/2017 . No. No significant O/L) abnormality could be observed. 78 Report No. Result: Acceptable Residual Life Assessment study of HRSG Page No. Component Interpretation Remarks 01 ECONOMISER ECONOMISER headers (I/L & O/L) Acceptabl headers (I/L & e were visually inspected.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS VISUAL INSPECTION REPORT COMPONENT ECONOMISER HEADERS (I/L & TEST: VISUAL O/L) INSPECTION EQUIPMENT AND MATERIAL USED Magnifying Glass Flash Light OBSERVATION Sl.

oil & grease. 79 Report No. F136/RLA/KRIBHCO/BLR1/07/2017 . 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 Specification ASTM E709-1995 OBSERVATION Sl. dust. paint. 01 No surface or sub surface defect Acceptable Circumferential welds observed. RESULT : Acceptable Residual Life Assessment study of HRSG Page No.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS 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. Area of examination Interpretation Remarks No.

RESULT : Acceptable Residual Life Assessment study of HRSG Page No. Developer. Of component : 250-300 Approx. 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. 80 Report No. Area of examination Interpretation Remarks No. OBSERVATION Sl. F136/RLA/KRIBHCO/BLR1/07/2017 . attachment observed. welds etc. No significant surface defect 01 Acceptable stub joints.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS DYE PENETRANT EXAMINATION COMPONENT: ECONOMISER HEADERS TEST: DYE PENETRANT (I/L & O/L) EXAMINATION EQUIPMENT AND MATERIAL USED 1) Penetrant. Circumferential welds.

Suppression Angle 8X9 2. Dia MHz (mm) db Amp. Range of Machine Settings CRT TECH. 81 Report No.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. F136/RLA/KRIBHCO/BLR1/07/2017 . RESULT : Acceptable Residual Life Assessment study of HRSG Page No.5/4 0 . Oil/ Mix EQUIPMENT CLIBRATION Surface condition: As cleaned Equipment calibrated by V1 & V2 Method : Direct Contact Block PROBE SIZE FREQ.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS ULTRASONIC FLAW DETECTION COMPONENT: ECONOMISER TEST: ULTRASONIC FLAW HEADERS (I/L & O/L) DETECTION EQUIPMENT AND MATERIAL USED 1) Ultrasonic Flaw Detector 2) Normal and Angle beam probe 3) Calibration block V1 & V2 4) Grease. Circumferential weld No recordable indication Acceptable 01 joints observed.

1 9.9 51. 4. 5. 5.1 25.8 51.1 19.1 13.0 8. 4. 4. 4.8 51. 5.2 4.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS ECONOMISER-2 COILS SR NO.9 51.8 51. 4.9 51.9 51.0 27.1 10. 4.0 51. 4.8 51.1 26. 4.9 51.0 51. 4.1 23. F136/RLA/KRIBHCO/BLR1/07/2017 .0 11.9 51.1 Residual Life Assessment study of HRSG Page No.0 51.1 ECONOMISER-1 COILS SR NO.0 5.0 51. 4.9 51. 5.1 18. 4. 5.2 3. 4.0 51.2 30.2 24.1 2.7 51. 5.2 51.8 51.7 51.9 51.2 51.9 51.9 51.0 7. 4. 4. 82 Report No. 4. 5. 5. 4.2 51. 4.8 51. 4. THICK OD 1.2 28. 4. 4. 5.8 51. 5.0 16.2 51. 4.1 3.0 51.0 21.8 51.1 51.1 51.2 9.0 51. 4.9 51.1 15.0 12.8 51.0 2.1 8.2 7. 5.1 5.0 10.9 51. 4.1 14. 4.0 20.9 51. 5. 4.1 6.0 29.1 4. 4.0 51.9 51.7 51.2 11.2 22. 5. 5.0 6. THICK OD 1.2 17.0 51. 5.

9 51. 4.0 22.2 28.9 51. 4.2 23.0 51.0 51. 4.1 20.0 15. 5.1 17.1 30. 4.2 27.2 25. 5.1 51.0 51. 5.1 26.9 51.9 51.9 51. 5.0 29.0 19.3 51. 4.6 51. F136/RLA/KRIBHCO/BLR1/07/2017 .0 16.0 24. 4.2 18. 5.7 51.7 51.9 51. 4. 5.0 51.0 21.7 51. 4.0 51. 4. 83 Report No.2 Residual Life Assessment study of HRSG Page No. 5.8 51. 4.1 13. 4. 4.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS 12.2 14.7 51.

2 3. THICK OD 1.0 12.3 2.1 7.3 5.0 51.1 4.3 25.1 19. 4.2 30.1 51.8 51.8 51.7 51. 4.0 28. 5.1 51.7 51. 5.T SIDE COILS SR NO.0 13.0 51. 4.7 51. 4. 4.0 17.9 51.9 51.7 51.1 51. 4. Test Observations No. 4.2 24. 4.8 51. 5.1 15. 1 Visual  Superheater headers (inlet & outlet) were visually Examination inspected and found in satisfactory condition.2 21.8 51.0 51.2 9.0 29.8 51. 4. 5. F136/RLA/KRIBHCO/BLR1/07/2017 .1 16. ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS ECONOMISER-2 G.0 8.2 6.8 51.7 51.0 26. 5.0 51.9 51.7 51. 84 Report No.1 10. 4.0 51. 5.2 14.1 20. 4.0 23.1 27.2 18. 4. 2 MPI  Magnetic particle inspection carried out for circumferential weld joints.9 51.7 51. No significant surface or sub-surface defect was observed. 4. 4. 4. 5.1 22.9 51.8 51. 4.9 51. 4. 4. 4. 4. 3 DPT  Dye penetrant was carried on circumferential weld Residual Life Assessment study of HRSG Page No.1 SUPERHEATER HEADERS (INLET & OUTLET) Sl.8 51. 4. 4.9 51. 5.3 11.

the components were found in satisfactory condition & suitable for further operation.6 N.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS joints. tube stub joints. Dye Penetrant test. 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. Details measurement measurements have been furnished separately in this chapter.A 4 35. attachment weld joints etc. re- inspection of component is recommended after 40. metallographic analysis & hardness measurement. Ultrasonic test. Degradation of pearlite phase is observed. Residual Life Assessment study of HRSG Page No. However. Degradation level IIL observed. Dimensional measurement: SH O/L HEADER THICK OD 1 34.A 2 35. dimensional measurement.4 N.A 3 34. 391 A.000 hrs.0 N.A Recommendation: Based on visual inspection. 85 Report No. Magnetic particle Inspection. 7 Replica  Microstructure reveals grains of ferrite and pearlite. F136/RLA/KRIBHCO/BLR1/07/2017 . 5 Dimensional  Dimensional measurement carried out.6 N. No significant surface defect observed. 4 UFD  Ultrasonic flaw detection carried out for circumferential weld joints. 8 Hardness  Hardness measured on replica locations and measured hardness found within acceptable limits. No significant discontinuity observed.

Component Interpretation Remarks 01 Superheater Superheater headers (I/L & O/L) Acceptable headers (I/L & were visually inspected. ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS VISUAL INSPECTION REPORT COMPONENT SUPERHEATER HEADERS (I/L TEST: VISUAL & O/L) INSPECTION EQUIPMENT AND MATERIAL USED Magnifying Glass Flash Light OBSERVATION Sl. No O/L) significant abnormality could be observed. No. 86 Report No. F136/RLA/KRIBHCO/BLR1/07/2017 . Result: Acceptable MAGNETIC PARTICLE EXAMINATION COMPONENT: SUPERHEATER TEST: MAGNETIC PARTICLE EXAMINATION HEADERS (I/L & O/L) Particular of Test: Wet fluorescent magnetic particle test Residual Life Assessment study of HRSG Page No.

Area of examination Interpretation Remarks No. ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS Surface Condition: Free from loose scale. 87 Report No. 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. F136/RLA/KRIBHCO/BLR1/07/2017 . 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) EQUIPMENT AND MATERIAL USED 1) Penetrant. dust. Of component : 250-300 Approx. 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 Specification ASTM E709-1995 OBSERVATION Sl. oil & grease. paint. Residual Life Assessment study of HRSG Page No. Developer.

F136/RLA/KRIBHCO/BLR1/07/2017 . Area of examination Interpretation Remarks No. Circumferential welds.300 48 80% Nil 450 Ф 10 mm SCANNING LEVEL : + 6 dB RECORDING LEVEL : 50 % FSH & ABOVE OBSERVATION Sl. Range of Machine Settings CRT TECH. Oil/ Mix EQUIPMENT CLIBRATION Surface condition: As cleaned Equipment calibrated by V1 & V2 Block Method : Direct Contact PROBE SIZE FREQ. Suppression Angle 8 X 9 mm/ 2. Area of Examination Interpretation Remarks Residual Life Assessment study of HRSG Page No. 88 Report No. Dia MHz (mm) db Amp. No significant surface defect 01 Acceptable stub joints. welds etc. ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS OBSERVATION Sl. RESULT : Acceptable ULTRASONIC FLAW DETECTION COMPONENT: SUPERHEATER HEADERS TEST: ULTRASONIC FLAW DETECTION (I/L & O/L) EQUIPMENT AND MATERIAL USED 1) Ultrasonic Flaw Detector 2) Normal and Angle beam probe 3) Calibration block V1 & V2 4) Grease. attachment observed.5/4 0 .

6.3 21.2 6. ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS No.64 <150 51.76 <150 6.80 <150 51.2 16. 6.51 <150 51.61 <150 51.1 22.98 <150 6. 6.53 <150 51.52 <150 6.33 <150 6.68 <150 6.84 <150 6.63 <150 6. 6.43 <150 51.49 <150 6.79 <150 6.96 <150 6.48 <150 6.43 <150 6. 6.43 <150 51.84 <150 51.2 18. 6. 6. 6.2 13.45 <150 51. 6. 6.52 <150 51.1 11.64 <150 51. 6. THICK UT-O THICK UT-O OD Residual Life Assessment study of HRSG Page No. 6. 01 Circumferential weld joints No recordable indication observed.65 <150 51.71 <150 51.53 <150 51.46 <150 6.5 7.42 <150 6. 6. THICK UT-O THICK UT-O OD 1.46 <150 6.0 4.0 15. 6.76 <150 6.67 <150 51.53 <150 51.1 27.0 28. 6.81 <150 51.78 <150 6.67 <150 6.77 <150 6.51 <150 6.54 <150 51. 6. 6.1 19.0 FSH-2(LOC-2) Sr no. 6.68 <150 51.2 30.67 <150 6.1 5.0 24.63 <150 51. F136/RLA/KRIBHCO/BLR1/07/2017 .52 <150 6.64 <150 51. 6.62 <150 6.33 <150 6. 89 Report No. 6.0 23.3 25.1 20. 6. 6.2 3. Acceptable RESULT : Acceptable FSH-2(LOC-1) Sr no. 6.52 <150 6. 6.3 12.54 <150 6.2 10.0 9.69 <150 51.43 <150 51.59 <150 51. 6. 6.70 <150 6.0 2. 6.60 <150 51.60 <150 51. 6. 6. 6.63 <150 51.1 14.2 26.47 <150 51.1 29.50 <150 6.92 <150 6.46 <150 51.0 8.61 <150 51.3 17.45 <150 6.

54 <150 6.44 <150 51.0 27.58 <150 51. 5.48 <150 6.4 <150 51.66 <150 6.63 <150 51.3 18. 6.69 <150 6.51 <150 6. 6. 6.1 30. 6. 6.2 17. 6. 5. 5.2 19. 5.53 <150 51.0 25.63 <150 51. 5.45 <150 51. 6.2 29. 6. 6.56 <150 6.64 <150 51.2 23. 6. 90 Report No. THICK UT-O OD 1. 6.2 <150 51.2 26.1 14. 6.42 <150 6. 6.46 <150 6.50 <150 51.62 <150 51.45 <150 6.62 <150 51.1 3. 6.2 15.2 2.2 <150 51.74 <150 51.41 <150 6. 5.0 <150 51.2 7.3 13.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS 1.39 <150 6.0 7. 5.64 <150 51.2 8.58 <150 6.4 11.89 <150 6.96 <150 6.46 <150 6. 5.37 <150 6.57 <150 513. 5.3 <150 51.1 8.1 16.0 2.92 <150 6. 6.1 12.61 <150 6. 6.72 <150 51.56 <150 51. 6.0 10.47 <150 51.71 <150 51.2 10.96 <150 6.57 <150 51.45 <150 51.1 11.76 <150 6.3 28.62 <150 6.0 9.62 <150 51.0 6.47 <150 51.3 <150 51.52 <150 51. 6. 5.1 Residual Life Assessment study of HRSG Page No. 6.33 <150 6.2 5.41 <150 51.4 <150 51.1 <150 51.3 SH-1 COILS SR NO. 6.1 12.1 4.1 22.0 3.53 <150 6. 6. 6. 6.1 21.2 9.3 4. 5. 6. F136/RLA/KRIBHCO/BLR1/07/2017 .80 <150 6.3 20.55 <150 6. 5. 6.24 <150 6.3 <150 51.0 13.84 <150 6.3 <150 51. 6.1 <150 51.1 5.52 <150 51.58 <150 6.65 <150 51.56 <150 51.22 <150 51. 5.0 <150 51. 6. 5.42 <150 6.52 <150 51.4 <150 51.53 <150 51. 6.77 <150 6. 6. 6.4 <150 51.0 24.42 <150 51. 6.2 14.

0 Residual Life Assessment study of HRSG Page No.5 <150 51.2 24. 5. 5. 5. 5. 5.4 <150 51. 5.3 <150 51.1 28.0 25.0 18. 5.1 21.4 <150 51.6 <150 51.0 23.0 29.2 <150 51.0 27. 5.3 <150 51. 5.1 30. 5. F136/RLA/KRIBHCO/BLR1/07/2017 .1 22.3 20. 5.1 19. 5. 5.2 <150 51.0 <150 51.ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS 15. 5.0 17. 5. 91 Report No.0 <150 51.4 <150 51.1 16.0 26.6 <150 51.4 <150 51.2 <150 51. 5.4 <150 51.6 <150 51.

92 Report No. Riser Tube .ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS Magnetic Particle Test Report Particular of test Wet fluorescent Magnetic Particle Testing Surface condition Free from loose scale. dust. Finding/ Observation Remark No. Saturated Tube 2 STUB JOINTS ALL No recordable Acceptable discontinuity observed Result Accepted All Defects Noticed Nil Residual Life Assessment study of HRSG Page No. Name of components Qty. tested A Down Comer . 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. F136/RLA/KRIBHCO/BLR1/07/2017 . paint. oil & grease.

ENERGO ENGINEERING PROJECTS LIMITED KRIBHCO SHYAM FERTILIZERS Residual Life Assessment study of HRSG Page No. 93 Report No. F136/RLA/KRIBHCO/BLR1/07/2017 .