Boiler Design and Operation Training Programme

Technical Services Inspection Module

TECHNICAL SERVICES UTILITY BOILER PLANT REVIEW

This review covers areas within the boiler envelope. For pressure parts the review covers the feed water from the Economiser Inlet Header to
the Boiler Stop Valves at the exit of the Superheater Outlet Headers and from Reheater Inlet Headers to Reheater Outlet Headers. On the Gas
pass side this report covers the pass from the windboxes to the expansion joint at the boiler gas outlet flue.
Common and ancillary plant such as Gas flue ducts, Air ducts, Fans, Airheaters, Blowdown vessels, Valves and Pipework are excluded from
this review.

Inputs from Mechanical Design, Process Design and Metallurgy Depts should be added to those from the Technical Services Review.
This document is intended to be generic with a column indicating the applicable boiler types. A further review with specific information on the
boiler to be inspected will be required.

Boiler Types:
A Natural Circulation
B Once/Through
C Coal Fired
D Gas Fired
E Oil Fired
F Waste Heat

Page 1 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 1 ECONOMISER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description Data Applicable
and Location
1 Boiler Flexible header flue gas seal (bellows) Visual survey A, B, C, D, Gas egress in HRSG
Economiser may deteriorate allowing air ingress, gas E, F
Inlet header egress.
wall seal.

2 Boiler top Support beams on roof support to be The beams should be A, B, C, D,

grillage checked for splaying. initially visually E.
support frame checked for bending
for and splaying at the
economiser heels of the channels
outlet header. and checked for
movement.
3 Economiser General or localised discolouration and Visual inspections of A, B, C, D, Rear wall of down pass is
bank tubes. dust deposition on external surfaces of tube bank and baffles. E, F. more likely to suffer from
tubes or walls above and below bank. . bypassing and erosion.
These provide indications of gas path
blockage and mal-distribution of gas
flows, including gas bypassing reducing
thermal performance and possibly
increasing grit erosion in areas of high
gas velocity.
4 Economiser Distortion of wall casings can allow Visual inspections of A, B, C, D,
bank bypassing mal-distribution of gas flows, tube bank and baffle. E, F.
including gas bypassing, reducing thermal
performance and possibly increasing grit
erosion in areas of high gas velocity.

Page 2 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 1 ECONOMISER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description Data Applicable
and Location
5 Economiser Distortion of individual or groups of tubes. Visual inspections. A, B, C, D,
bank tubes. E, F.
6 Economiser External corrosion or mechanical damage Visual inspections of A, B, C, D, On-line corrosion only
bank tubes. of tubes or fins. tubes and fins. E, F. likely during extended
Off-line, sub dew point corrosion may UT thickness tests, outage of feedwater
increase during 2-shifting or prolonged possibly using heaters.
shutdowns. Gravimat for more
extensive survey.
7 Economiser Off-line internal corrosion of tubes. The UT thickness tests, A, B, C, D, Consider preservation
bank tubes. risk of oxygen ingress to allow this is possibly using E, F during prolonged outages,
increased during intermittent operation Gravimat for more including with Nitrite
regimes and prolonged outages. extensive initial Borax. (not for OT boilers)
survey.
Remote visual
inspections.
8 Economiser On-line internal Flow Accelerated UT tests at bends and A, B, C, D, LP Circuits on HRSG
bank tubes. Corrosion (FAC) of tubes. The risk of this at flow disturbance E, F. particularly vulnerable.
is also increased during 2-shifting when areas.
feed water chemistry may be disturbed
and feedwater temperature may be lower Remote visual
than normal. inspections.

Page 3 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 1 ECONOMISER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description Data Applicable
and Location
9 Economiser Sootblower erosion. Visual inspection with A, B, C, D, Shields may be required if
bank tubes. UT thickness E. erosion severe.
investigation on any
thinned areas.

Checks adjacent to
blowers with particular
attention at lance
entry area, where
condensate may be
present in the steam.

10 Economiser Boilers with longer headers within the gas Header cap should be A, B, C, D,
bank inlet pass are considered vulnerable to fatigue removed for remote E.
headers failures of the tube stub welds due to visual inspections.
hogging. Stub weld cracking
externally due to
There is also a risk during hot or warm hogging. MPI and UT.
starts and/or 2-shifting when relatively Internal ligament or
cold feed water may be thermally shock star cracking from
the header during steam drum level filling thermal shocking. UT
or boiler restart. or radiographic testing
required.

Page 4 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 1 ECONOMISER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description Data Applicable
and Location
11 Economiser Headers in gas stream may be subject to Visual inspection of A, B, C, D, Significant internal
tube bank external corrosion or dust erosion. header and support E. damage unlikely.
outlet headers attachments.
12 Economiser General checks for any, distortion, Visual inspection A, B, C, D,
outlet gas displacement or support cradle E.
down pass attachment problems that may be
sling tubes. indicative of uneven loading or
overheating.

13 Economiser External off-line, acid dew point corrosion Visual inspections, UT A, B, C, D,

outlet gas may increase during prolonged thickness tests, E.
down pass shutdowns. possibly using
sling tubes. Gravimat for more
extensive initial
survey.

Page 5 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 1 ECONOMISER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description Data Applicable
and Location
14 Economiser Sootblower erosion. Visual inspection with A, B, C, D, Shields may be required if
outlet gas UT thickness E. erosion severe.
down pass investigation on any
sling tubes. thinned areas.

Checks adjacent to
blowers with particular
attention at lance
entry area, where
condensate may be
present in the steam.

15 Economiser Roof penetration refractory seals. Loss of Visually inspect all A, B, C, D,

gas down seal may allow gasses to enter the top penetrations. E.
pass sling deadspace with potential for overheating
tubes roof and explosion during combustion upset.
penetrations.
16 Economiser Internal or external damage. Visual inspection of A, B, C, D, Significant internal or
sling tube header. E. external damage unlikely.
outlet header.
17 Economiser Cold formed bend (cold creep damage) Visual checks. A, C, D, E. High consequence of
sling tube and corrosion at horizontal sections Dimension checks for failure if pipe located
outlet header (especially after chemical cleans) ovality. RVI at cut outside deadspace.
risers. outs. UT thickness
and flaw detection.

Page 6 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 1 ECONOMISER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description Data Applicable
and Location
18 Economiser Support integrity. Visual inspection of A, C, D, E.
stringer top suspension
header outlet attachment, slings,
risers. riser pipe support
frames and fasteners.
19 Economiser Support integrity and correct loading. If Visual inspection of A, B, C, D,
outlet gas support welded to tubes, failures due to support leaf springs, E.
down pass fatigue at attachment weld. slings, clevis joints,
sling tube header attachments
supports and fasteners.

MPI at tube
attachment welds, if
applicable.
20 Economiser Support integrity and correct loading. Visual inspection of A, B, C, D,
sling tube support leaf springs, E.
outlet header slings, clevis joints,
top header header attachments
steelwork and fasteners.
supports .
21 Economiser Cold formed bend (cold creep ) damage RVI at cut outs. UT A, C, D, E. High consequence of
riser pipes and corrosion fatigue at horizontal bends thickness and flaw failure if pipe located
Boiler top (especially after chemical cleans) detection. outside deadspace.
dead space.

Page 7 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 2 FURNACE WATER WALLS

No Boiler Plant Design Issue/Concern Inspection Boilers Comments
Description and Data Applicable
Location
1 Boiler wall tubes. Fretting of the wall tubes at the Visually inspect these locations for A, B, C, D,
roof tube penetrations, especially fretting. Any evidence of fretting E.
where the gaps between the tubes must be followed by an estimation
at the point of penetration is small of loss of thickness by UT
and could allow the tubes to touch thickness checks.
even through normal plant
vibration.
2 Boiler wall inlet Possible twisting of headers that Visual inspection of each header A, B, C, D,
headers. have a single point support. This support lug fixing hole for ovality. E.
could cause cracking in end stubs. MPI/UT inspections of stubs if
defects found.
3 Boiler wall outlet Longer outlet headers can suffer The outer tube stub connections at A, B, C, D, Applies to long
headers in top from hogging, particularly if each end of the header should be E. headers.
dead space. operated under two shifting visually inspected and the welds
regime, and suffer from antler onto the header checked using MPI
failure. As the headers heat up at inspections
start up the amount of expansion
in the outlet header versus front
wall expansion could cause the
header stubs to crack due to
fatigue induced by stub/antler
bending at the extreme ends of the
header.

Page 8 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 2 FURNACE WATER WALLS

No Boiler Plant Design Issue/Concern Inspection Boilers Comments
Description and Data Applicable
Location
4 Boiler wall outlet Support integrity and correct Visual inspection of support leaf A, B, C, D, If abnormal
header supports. loading. springs, slings, clevis joints, header E. loading is
attachments and fasteners. suspected a full
boiler weighing
survey should be
carried out.
5 Refractory lined Seal boxes local to wall should be Full visual survey at each outage. A, B, C, D,
seal boxes at checked for tearing particularly if E.
openings and box includes circuits which may
points of have differential expansions at
discontinuity in start up.
the membrane
walls
6 Boiler wall tubes. General or localised discolouration Visual inspections looking for A, B, C, D,
and deposition/slagging on indications of general or localised E.
external surfaces of tubes. combustion problems including
poor atomisation, flame
impingement etc..

Page 9 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 2 FURNACE WATER WALLS

No Boiler Plant Design Issue/Concern Inspection Boilers Comments
Description and Data Applicable
Location
7 Boiler wall tubes. General misalignment, bowing or Visual inspections checking for any A, B, C, D,
displacement of the membrane evidence of: E.
tube panels.
1. Furnace
explosions/implosions;
2. Evidence of overheating;
3. Expansion restraints;
4. Suspension supports
problems;
5. Buckstay attachments defects;
6. Windbox or wall deadspace
attachment problems;
7. Wall restraint attachment
defects;
8. Superheater or reheater
penetrations problems.
8 Boiler wall tubes. External blistering, swelling, Visual inspections checking for A, B, C, D,
scaling, or distortion of individual indications of overheating due to E.
tubes. excessive heat input or reduced
heat transfer resulting from internal
flow restrictions or fouling.

Further investigation by RVI and

metallography.
9 Boiler front wall External or fireside corrosion of Visual inspections, UT thickness A, B, C, D,
tubes. tubes around above and below tests, possibly using Gravimat for E.
burner level. more extensive initial benchmark
survey.
Page 10 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 2 FURNACE WATER WALLS

No Boiler Plant Design Issue/Concern Inspection Boilers Comments
Description and Data Applicable
Location
10 Boiler wall hopper Mechanical damage to hopper Visual inspections A, B, C, D,
tubes. tubes by falling slag and debris or E.
by slag removal activities.
11 Boiler wall side Localised erosion of tubes due to Visual inspections with targeted UT A, B, C. Also applies to
wall tubes concentrated ash flows cascading thickness checks. division wall, if
adjacent to down walls and flowing to hopper applicable.
hopper and in boilers fired with high ash coal,
hopper tubes at or coals with abrasive ash.
tubes side wall.
12 Hopper Throat Moisture due ash hopper quench Visual inspections with targeted UT A, B, C.
tube off-line sprays left running with boiler shut thickness checks.
corrosion. down accelerates off-line corrosion
of tubes.
13 Boiler wall tubes. Internal deposition Tube sample to be cut out from A, B, C, D, Recommend 1
high heat flux area of furnace wall, E. sample from
above burners for qualitative and each wall just
quantitative analysis of deposits. above burner
Results to be used for water belt.
chemistry control and chemical
clean requirement assessment.
(Consider chemical clean if deposit
>100microns)
14 Boiler wall tubes. Internal on-line corrosion Checks for corrosion in the above A, B, C, D,
(Hydrogen Damage, Caustic tube sample and by RVI of tube E.
Gouging and Acid Phosphate above and below cut-out. Fast
corrosion). scanning UT, Gravimat to be used
Internal off-line by oxygen pitting. to determine extent of damage if
on-line corrosion suspected.
Page 11 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 2 FURNACE WATER WALLS

No Boiler Plant Design Issue/Concern Inspection Boilers Comments
Description and Data Applicable
Location
15 Buckstay framing, Highly stressed areas and Visual survey externally checking A, B, C, D, Sample locations
windbox and deformation may result from for any distortion that may be E. to be inspected
support restrictions in the thermal indicative of problems. Remove dependant on
attachments to movement of the boiler at insulation and investigate the plant experience.
wall tubes. attachment points. Corrosion attachments to tubes in these If subcooling
fatigue and mechanical fatigue areas with visual inspections, problem persists
cracking are more likely to occur targeted MPI and UT checks. pumped
under cyclic 2-shifting loading. Particular attention should be paid circulation may
to the following areas: be required
Furnace wall ‘subcooling’ during a during shutdown
shut down and subsequent hot or 1. Windbox or deadspace period.
warm start may lead to excessive attachment areas;
differentials leading to fatigue 2. Wall restraint attachments ;
cracking problem at attachments 3. Buckstay corners;
and between adjacent circuits. 4. Lower hopper beams
supporting inlet header and/or
downcomers.

Page 12 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 2 FURNACE WATER WALLS

No Boiler Plant Design Issue/Concern Inspection Boilers Comments
Description and Data Applicable
Location
16 Membrane, Corrosion fatigue and mechanical Visual inspection with targeted MPI A, B, C, D, Defects may
scallop plate and fatigue cracking can be initiated in and UT checks if defects are found E. arise internally
filler block areas where there are higher or failures are experienced. (corrosion
attachments to stresses due to differential thermal Particular attention should be given fatigue) or
wall tubes at and mechanical movements. to the following areas: externally
junctions, This will be exacerbated under (mechanical
separations, cyclic 2-shifting loading. 1. Membrane at hopper throat; fatigue).
penetrations and 2. Membrane at arch nose;
terminations. 3. Top of hopper level at junction
with division wall tube;
4. Hopper slope to side and
division wall seals.
5. Arch junction with rear wall;
6. Arch to side and division wall
seals.

17 Furnace Sootblower Erosion - damage to Visual inspection with UT thickness A, B, C, D,

sootblower furnace tubes by entrained dust investigation on any thinned areas. E.
erosion erosion.
18 Furnace water Thermal fatigue damage results Visual, MPI and tube sample for A, B, C Only applies to
cannon or water from improperly set up or operated analysis if damage detected. high ash, low ash
blower damage. cannons or blowers. fusion point
coals. E.g. PRB.
19 Boiler wall tubes. Possible fretting of the S/H and Visually inspect. Any evidence of A, B, C, D,
R/H elements at walls. fretting must be followed by an E.
estimation of loss of thickness and
UT thickness checks, if accessible.

Page 13 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 2 FURNACE WATER WALLS

No Boiler Plant Design Issue/Concern Inspection Boilers Comments
Description and Data Applicable
Location
20 Boiler wall tubes Loss of seal may allow flue gas to Visual inspection of penetration, A, B, C, D, This is a
at penetrations enter deadspaces with potential including refractory from gas side. E. particular
seals. for overheating and explosion concern for gas
during combustion upset firing.
conditions.
21 Boiler wall inlet Checks for debris in the headers. RVI of header via caps. A, B, C, D, Infrequent
headers. E. inspection, after
acid clean
22 Boiler wall supply Cold formed bend (cold creep ) RVI at any cut outs. UT thickness A, C, D, E. High
pipes damage and corrosion fatigue at and flaw detection. consequence of
horizontal bends (especially after failure if pipe
chemical cleans) located outside
deadspace.
23 Boiler wall supply Support integrity and correct Visual inspection of suspension A, C, D, E.
pipes loading. attachment, beams, slings ,
variable load supports, supply pipe
attachments and fasteners.
24 Boiler wall riser Cold formed bend (cold creep ) RVI at cut outs. UT thickness and A, C, D, E. High
pipes damage and corrosion fatigue at flaw detection. consequence of
Boiler top dead horizontal bends (especially after failure if pipe
space. chemical cleans) located outside
deadspace.
25 Boiler wall riser Support integrity. Visual inspection of suspension A, C, D, E.
pipes attachment, slings, riser pipe
Boiler top dead support frames and fasteners.
space.

Page 14 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 2 FURNACE WATER WALLS

No Boiler Plant Design Issue/Concern Inspection Boilers Comments
Description and Data Applicable
Location
26 Boiler Side and Cracking propagating into tubes Visual and MPI checks A, C, D, E.
Division Walls can occur at membrane junction
panel junctions between two panels in bottom and
at hopper slope interface.
27 Furnace arch Confirm that buckstay and other Visual inspection within arch A, B, C, D,
deadspace structural steelwork has not deadspace. E.
structural suffered any overheating damage
steelwork. or distortion.
28 Furnace rear wall Dust erosion of tubes. Visual inspection. UT thickness in A, B, C, D, Particular
sling tubes and suspect areas. E. attention should
vestibule exit be paid to areas
screen. near vestibule
floor.

Page 15 of 40

TABLE 3 FURNACE ROOF TUBES AND DOWNPASS REAR WALL (GENERALLY STEAM COOLED)
No Boiler Plant Design Issue/Concern
Description and Data
Location
1 Boiler rear wall General or localised
and roof tubes. deposition/slagging on
external surfaces of tubes.
2 Boiler rear wall General misalignment, bowing
and roof tubes. or displacement of the tubes
and tube panels, if applicable.
This includes sagging roof
tubes.
3 Boiler rear wall External blistering, swelling,
and roof tubes. scaling, or distortion of
individual tubes.
4 Boiler rear wall External off-line corrosion of
and roof tubes. tubes.
5 Boiler rear wall Dust erosion of roof and of
and roof tubes. rear wall tubes at gas leakage
paths at areas of gas flow
impingement or accelerated
gas flow.
Page 16 of 40
Boiler Design and Operation Training Programme
Technical Services Inspection Module
Inspection Boilers Comments
Applicable
Visual inspections looking for A, B, C, D, E.
indications of general or
localised problems.
Visual inspections checking for A, B, C, D, E. Sagging roof tubes
any evidence of furnace may expose roof
explosions/implosions, signs of refractory and
overheating or problems with deadspace casing
expansion movement, to damage,
suspension supports and depending on the
buckstay attachments. arrangement.
Visual inspections checking for A, B, C, D, E.
indications of overheating due
to excessive heat input or
reduced heat transfer resulting
from internal flow restrictions or
fouling.
Further investigation by RVI and
metallography.
Visual inspections, UT thickness A, B, C, D, E.
tests.
Visual inspections, UT thickness A, B, C, D, E.
tests.
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 3 FURNACE ROOF TUBES AND DOWNPASS REAR WALL (GENERALLY STEAM COOLED)
No Boiler Plant Design Issue/Concern Inspection Boilers Comments
Description and Data Applicable
Location
6 Boiler rear wall Internal deposition and on/off- RVI checks of horizontal roof A, B, C, D, E. Infrequent check.
and roof tubes. line corrosion. tubes from header. UT
thickness checks if problem
confirmed.
7 Buckstay framing, Highly stressed areas and Visual survey externally, A, B, C, D, E. Roof and rear wall
and support deformation may result from checking for any distortion that circuits are usually
attachments to restrictions in the thermal may be indicative of problems. steam circuits,
rear wall. movement of the boiler at Remove insulation and which are more
attachment points. Corrosion investigate the attachments to vulnerable to
fatigue and mechanical tubes in these areas with visual differential heating
fatigue cracking are more inspections, targeted MPI and and expansion.
likely to occur under cyclic 2- UT checks. .
shifting loading.
8 Boiler rear wall Defects on weld of support to Visual inspection of support, A, B, C, D, E.
supports, including tube. slings, frames and fasteners.
weld attachments
to tubes if Visual inspections of weld
applicable. attachment with 100% MPI if
defect identified or repeat failure
experienced.
9 Boiler roof tube Integrity, security and loading Visual inspection of suspension A, B, C, D, E.
support of roof tube support slings. attachment, slings, frames and
attachments. fasteners.

Confirm support slings are,

loaded.

Page 17 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 3 FURNACE ROOF TUBES AND DOWNPASS REAR WALL (GENERALLY STEAM COOLED)
No Boiler Plant Design Issue/Concern Inspection Boilers Comments
Description and Data Applicable
Location
10 Boiler roof and Fretting at S/H, R/H, Visual inspections. Any A, B, C, D, E.
rear wall tubes. economiser and wall tube evidence of fretting must be
penetrations. followed by an estimation of
loss of thickness and UT
thickness checks, if accessible.
11 Inlet header Saturated steam. RVI inspections for evidence of A, B, C, D, E.
. Checks for carry over in Drum mechanical carryover.
boilers
12 Boiler roof and Carry over of solids from RVI inspections from inlet A, C, D, E.
rear wall tubes. boiler water in the steam header
drum. Deposits can be baked
onto tubes. This can lead to
increased tube metal
temperatures and under
deposit on line corrosion. (If
caustic dosed to drum)
13 Outlet header Fatigue to stubs at end of Visual inspections. MPI, UT A, B, C, D, E.
headers due to thermal checks if defects found.
differentials in heating circuits.
14 Boiler saturated Support integrity and correct Visual inspection of suspension A, B, C, D, E.
steam pipes loading. attachment, beams, slings,
variable load supports, supply
pipe attachments and fasteners.

Page 18 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 4 SUPERHEATER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
1 Superheater bank General or localised Visual inspections of tube A, B, C, D, E,
tubes. discolouration and bank, baffle and walls. F.
deposition/slagging on
external surfaces of tubes.
Checks for indications of gas
side blockage and
maldistribution of gas flows,
including gas bypassing.

Page 19 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 4 SUPERHEATER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern
Description and Data
Location
2 Superheater bank Visual checks should be
tubes. carried out for blistering,
swelling, scaling, or
distortion of individual tubes.
These indications of
overheating may be due to
excessive heat input,
reduced heat transfer
resulting from internal flow
restrictions, fouling or
inappropriate material
selection.
If overheating is detected the
root cause should be
investigated, e.g.
Inspection
Visual inspections.
In situ creep life assessment
by metallurgical replication
and/or TLP.
Boiler Comments
Applicable
A, B, C, D, E, Remnant life
F. assessment of tubing.
Particular attention
should be given to
the locations at the
highest steam
temperature location
for each material and
to the areas subject
to the highest heat
flux.

 Uncontrolled primary
SH outlet temp;
 Water logging a start
up;
 Tube blockage by
exfoliated magnetite
accumulations;
 Element
misalignment;
 Material selection.

Page 20 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 4 SUPERHEATER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern
Description and Data
Location
3 Superheater bank On-line coal or oil ash
tubes. corrosion may occur if the
tubes or attachments reach
the ash fusion temperature
for the fuel being fired.
External corrosion or tubes
by off-line, acid dew point
corrosion may increase
during prolonged shutdowns.
Inspection
Visual inspections, UT
thickness tests, possibly
using Gravimat for more
extensive initial benchmark
survey.
Boiler Comments
Applicable
A, B, C, D Oil or coal ash
corrosion would
generally attack tube
alignment devices
first, dependant on
material selection.

Page 21 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 4 SUPERHEATER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
4 Superheater bank Alignment of elements within Visual inspections noting A, B, C, D, E. Inspection from both
tubes. banks and tube within misalignment greater than 1 sides of tube bank.
elements. Misalignment can: tube diameter.

1. Disturb gas flow Check integrity of uncooled

distribution reducing heat alignment devices. These
exchange efficiency: devices may also be subject
2. Result in condensate to coal or oil ash corrosion in
retention and possible the hotter passes.
corrosion in sagged
tubes:
3. Increase sootblower and
dust erosion:
4. Increase fretting
damage:
5. Result in failure due to
loss of support.
6. Increase the oil ash
corrosion due to radiant
heat penetration.
5 Superheater bank Off-line internal corrosion of UT thickness tests. A, B, C, D, E, Pendant and sagged
tubes. tubes. If off-line storage is F. horizontal tubes will
not effective during RVI from tube sample cut- retain water during
intermittent operation and out. shut downs.
prolonged storage periods.

Page 22 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 4 SUPERHEATER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
6 Superheater bank Magnetite exfoliation can Cut tube from hotter end of A, B, C, D, E. Magnetite exfoliation
tubes. cause tube blockages and the bank to check for will increase with
Solid Particle Erosion (SPE) magnetite exfoliation by RVI plant cycling.
thinning at tube bends. inspection.

This will determine any

requirement for further UT
checks to check for SPE.

The original magnetite

thickness will also provide an
indication of remaining creep
life of the tube, determining
need for more extensive TLP
survey.
7 Superheater bank Sootblower erosion. Visual inspection with UT A, B, C, D, E. Shields may be a
tubes. thickness investigation on useful preventitative
any thinned areas. measure.

Checks adjacent to blowers

with particular attention at
lance entry area, where
condensate may be present
in the steam.

Page 23 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 4 SUPERHEATER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
8 Superheater bank Dust erosion. Visual inspection with UT A, B, C. Particular attention
tubes. thickness investigation on should be given to
any thinned areas. Thinning areas likely to have
usually worse at 10 and 2 higher gas flows due
o’clock positions. (Gas flow to:
12 o’clock)
Duct geometry;
Misalignment of
elements/tubes;
Blockage of gas path.
9 Superheater bank Fretting of tubes with Any evidence of fretting A, B, C, D, E, Fretting can be by
tubes. adjacent tubes from other should be followed by an F. repeated impact or
banks/ walls and at estimation of loss of expansion/contraction
inlet/outlet penetrations. thickness and UT thickness of touching tubes.
checks if accessible.
10 Superheater bank Inlet and outlet tube Visual inspection of A, B, C, D, E, Loss of seal may
tubes. penetration damage, penetration, including F. allow gases to enter
including refractory seals. refractory from gas side. deadspaces with
potential for:
Overheating in
deadspace; Erosion;
Explosion of
unburned fuel during
combustion
excursions.

Page 24 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 4 SUPERHEATER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
13 Superheater Stress Corrosion Cracking RVI from tube sample cut-out. A, B, C, D, E, F More likely in SS SH
bank tubes. (SCC) from dissolved or if chloride or caustic
suspended solids deposited UT flaw detection, contamination
in the superheater by: radiography. present.

1. Steam drum level

control excursions;
2. Mechanical carry
over from the steam
drum;
3. Attemperator
damage;
4. Attemperator control
excursions,
5. Water chemistry
upset contaminating
spray water;
6. Failure to backfill
during chemical
clean.

14 Superheater Thermal fatigue due to inlet Header caps should be A, B, C, D, E, F

bank headers, attemperation and start up
including stub condensate drainage
headers. problems. This can result in
internal ligament or star
cracking.
removed for RVI. If cracking
found investigate with TOFD
or radiographic testing .

Page 25 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 4 SUPERHEATER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
15 Superheater Overheating/creep damage. Metallography. A, B, C, D, E.
outlet headers, F.
including stub
headers.
16 Superheater inlet Support integrity and thermal Visual inspection of supports A, B, C, D, E. Also check integrity
and outlet header movement. and anchor, including slings, F. and setting of
supports. header attachments and pipework supports
Stub damage may result fasteners. and anchor local to
from SH outlet pipework header.
loads. MPI checks on selected
stubs.

17 Superheater inlet Deterioration of header Visual survey. A, B, C, D, E,

and outlet deadspace penetration flue F.
headers. gas seal (bellows).

Page 26 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 8 REHEATER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
1 Reheater bank General or localised Visual inspections of tube A, B, C, D, E,
tubes. deposition/slagging on bank. F.
external surfaces of tubes.
Checks for indications of gas
path blockage and
maldistribution of gas flows,
including gas bypassing.
2 Reheater bank External blistering, swelling, Visual inspections. A, B, C, D, E,
tubes. scaling, or distortion of F.
individual tubes. In situ creep life assessment by
metallurgical replication and/or
Overheating may due to TLP.
excessive heat input or
reduced heat transfer
resulting from internal flow
restrictions or fouling.

Page 27 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 8 REHEATER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
3 Reheater bank Alignment of elements within Visual inspections noting A, B, C, D, E, Thinner walled RH
tubes. banks and tubes within misalignment greater than 1 F. tubes are more prone
elements. Misalignment can: tube diameter. to distortion.

1. Disturb gas flow Check integrity of uncooled Check temps

distribution reducing heat alignment devices. These monitored at start up
exchange efficiency: devices may also be subject to before cooling flow
2. Result in condensate coal or oil ash corrosion in the established through
retention and possible hotter passes. RH tubes.
corrosion in sagged .
tubes:
3. Increase sootblower and
dust erosion:
4. Increase fretting damage:
5. Result in failure due to
loss of support.
6. Increase the oil ash
corrosion.

Page 28 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 8 REHEATER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
4 Reheater bank External corrosion or tubes. Visual inspections, UT A, B, C, D, E, Any corrosion is more
tubes. thickness tests, possibly using F. significant on these
On-line coal or oil ash Gravimat for more extensive thinner walled tubes.
corrosion may attack tubes or initial benchmark survey.
more likely alignment devices
in higher steam and gas
temperature zones.

Off-line, acid dew point

corrosion may increase
during 2-shifting or prolonged
shutdowns.
5 Reheater bank Off-line internal corrosion of RVI inspections. A, B, C, D, E, Any corrosion is more
tubes. tubes. In drum boilers F. significant on these
mechanical carryover of UT tests and radiography at thinner walled tubes.
sodium sulphate during bottom of pendants and on
operation is known to lower sagged tube sections.
preferentially attack reheater
tubes. This will be
accelerated by any oxygen
ingress during 2-shifting and
intermittent operation
regimes.

Page 29 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 8 REHEATER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
6 Reheater bank Magnetite exfoliation can Cut tube from hotter end of the A, B, C, D, E, Magnetite exfoliation
tubes. cause tube blockages and bank to check for magnetite F. will increase with
Solid Particle Erosion (SPE) exfoliation by RVI inspection. plant cycling.
thinning at tube bends.
This will determine any Any corrosion is more
requirement for further UT significant on these
radiography checks to check thinner walled tubes.
for SPE.

The original magnetite

thickness will also provide an
indication of remaining creep
life of the tube, determining
need for more extensive TLP
survey.
7 Reheater bank Sootblower erosion. Visual inspection with UT A, B, C, D. Thinner tubes in RH
tubes. thickness investigation on any make this more
thinned areas. important.

Checks adjacent to blowers Shields may be a

with particular attention at useful preventative
lance entry area, where measure.
condensate may be present in
the steam.

Page 30 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 8 REHEATER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
8 Reheater bank Dust erosion. Visual inspection with UT A, B, C. Particular attention
tubes. thickness investigation on any should be given to
thinned areas. Thinning areas likely to have
usually worse at 10 and 2 higher gas flows due
o’clock positions. (Gas flow 12 to:
o’clock) Duct geometry;
Misalignment of
elements/tubes;
Blockage of gas path.

Thinner tubes in RH
make this more
important.
9 Reheater bank Fretting of tubes with Any evidence of fretting should A, B, C, D, E, Fretting can be by
tubes. adjacent tubes from other be followed by an estimation of F. repeated impact or
banks/ walls and at loss of thickness and UT expansion/contraction
inlet/outlet penetrations. thickness checks if accessible. of touching tubes.

Thinner tubes in RH
make this more
important.

Page 31 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 8 REHEATER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
10 Reheater bank Inlet and outlet tube Visual inspection of A, B, C, D, E, Loss of seal may
tubes. penetration damage, penetration, including F. allow gases to enter
including refractory seals. refractory from gas side. deadspaces with
potential for:

Overheating in
deadspace; Erosion;
Explosion of
unburned fuel during
combustion upsets.
11 Reheater bank Thermal fatigue due to inlet Header caps should be A, B, C, D, E, F
inlet headers attemperation. This can result removed for RVI. If cracking
in internal ligament or star found investigate with TOFD or
cracking. radiographic testing .
12 Reheater bank Stub fatigue damage due to Visual checks. A, B, C, D, E, Confirm CRH
inlet headers unexpected pipework loading. F. pipework supported
MPI/UT checks on selected and anchored
stubs. correctly.
13 Reheater bank Overheating/creep damage. Visual checks. A, B, C, D, E, Confirm HRH
outlet headers F. pipework supported
Stub fatigue damage due to Metallography replication and anchored
unexpected pipework loading. checks. correctly.

MPI/UT checks on selected

stubs.

Page 32 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 8 REHEATER ELEMENTS AND HEADERS

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
16 Reheater inlet and Support integrity and thermal Visual inspection of supports, A, B, C, D, E,
outlet header movement. including slings, header F.
supports and attachments and fasteners.
anchors.
17 Reheater inlet and Deterioration of header Visual survey. A, B, C, D, E,
outlet headers. deadspace penetration flue F.
gas seal (bellows)..

Page 33 of 40

TABLE 12
No Boiler Plant Design Issue/Concern
Description and Data
Location
1 Attemperators Attemperator spray nozzles
internal inspection. and thermal sleeves are
subjected to high stresses due
to the temperature
differentials resulting in
thermal fatigue failures over
time. Cycling plant under 2-
shift operation will increase
this risk. If liner damage not
repaired the attemperator
pipework may be damaged by
thermal fatigue.
2 Attemperator Support integrity and thermal
supports. movement.
Page 34 of 40
Boiler Design and Operation Training Programme
Technical Services Inspection Module
ATTEMPERATORS
Inspection Boiler Comments
Applicable
Cut spray water pipe and A, B, C, D, E, F.
remove the spray nozzle. Visual
inspection of nozzle checking:
1. Weld integrity;
2. Nozzle integrity, including
wear;
3. Nozzle blockage.
4. MPI nozzle welds.
RVI of venturi lining, including
liner section butt welds, liner
inlet support rings, including
welds and the liner outlet
support pads, including welds.
Visual inspection of support A, B, C, D, E, F.
attachments slings, header
attachments and fasteners for
attemperator and spray water
line.
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 13 STEAM DRUM

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
1 Steam drum The condition of the drum Visual inspection over whole A, C, D, E, F
internal internal surfaces should be length of the drum prior to any
inspections. recorded above and below internal dismantling or cleaning.
the water line, including the
descriptions, location and
approximate quantities of any
accumulations. This
information provides a
valuable insight into:

1. Boiler water chemistry;

2. Drum steam/water
separation performance;
3. Drum level control.

Page 35 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 13 STEAM DRUM

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
2 Steam drum The following are the main Visual inspections after internal A, C, D, E, F
internal pressure damage mechanisms found removal:
part visual on drum pressure parts,
inspections. including welds: 1. Circumferential shell welds;
2. Longitudinal shell welds;
1. Fatigue; 3. Baffle attachment welds;
2. Corrosion fatigue; 4. Cyclone and primary
3. Thermal fatigue; scrubber attachment welds;
4. Corrosion; 5. Secondary scrubber
5. Erosion. attachment welds;
6. Access door hinge
2-shifting cycling will increase attachment welds.
the potential for damage to
more highly stressed areas.
3 Steam drum Defects on pressure part MPI tests on areas listed above A, C, D, E, F
internal NDT welds. 2-shifting cycling will for internal visual inspections.
testing. increase the potential for UT also to be used if any
damage to more highly indications found.
stressed areas.
This will require removal of
internals in the area to be
tested.

Page 36 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 13 STEAM DRUM

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
4 Steam drum Damage or displacement to Visual inspection over whole A, C, D, E, F
internal the internals can affect the length of the drum prior to any
equipment following: internal dismantling or cleaning of:
inspections. 1. Baffle plate integrity;
2. Cyclone integrity, orientation
1. Boiler circulation
and alignment;
efficiency; 3. Primary scrubber and
2. Steam water separation; perforated pyramid integrity
3. Effective control of water and fouling;
and steam chemistry; 4. Secondary scrubber and drain
4. Water level control. pot integrity and fouling;
5. Feedwater pipe integrity and
port obstruction;
6. HP dosing pipe integrity, port
orientation and obstruction;
7. Blowdown pipe integrity, port
orientation and obstruction.
8. Long and short range water
level pipe integrity and
opening obstruction;
9. Downcomer debris screen
and vortex inhibitor integrity.
10. Blockages of any shell
penetrations;
11. Condition of access door
sealing faces and studs.

Page 37 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 13 STEAM DRUM

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
5 Steam drum Defects on pressure part Visual inspections after A, C, D, E, F
external pressure welds. 2-shifting cycling will insulation removal:
part visual increase the potential for
inspections. fatigue damage to more 1. Circumferential shell welds;
highly stressed areas. 2. Longitudinal shell welds;
3. Downcomer shell and
nozzle welds;
4. Riser shell and nozzle
welds;
5. Economiser outlet shell
and nozzle welds;
6. Safety valve shell and
nozzle welds.
6 Steam drum Defects on pressure part MPI tests on areas listed above A, C, D, E, F
external pressure welds. 2-shifting cycling will for external visual inspections.
part NDT testing. increase the potential for UT and radiography testing
damage to more highly could also be used if any
stressed areas. indications found.
7 Steam drum Any damage, distortion or Visual inspection of laminated A, C, D, E, F
support slings. displacement of steam drum ‘U’ slings checking integrity and
‘U’ slings. correct installation of slings,
including fasteners and bearing
pads around drum.
MPI sling attachments.

Page 38 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 13 STEAM DRUM

No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
8 Steam drum sling Support integrity and correct Visual inspection of support leaf A, C, D, E, F
deck steelwork loading. springs and vertical slings.
supports

Page 39 of 40
 Boiler Design and Operation Training Programme

Technical Services Inspection Module

TABLE 14 DOWNCOMERS
No Boiler Plant Design Issue/Concern Inspection Boiler Comments
Description and Data Applicable
Location
1 Downcomer Confirm satisfactory Visual from available access. A, C, D, E, F
external expansion movement by Hot and cold expansion
inspection. external visual inspections measurements.
checking alignment and any
distortion to attachments, e.g.
drains.
2 Downcomer weld Defects on combined MPI tests on areas listed above A, C, D, E, F Infrequent
inspections. pressure part and load for external visual inspections. inspection.
carrying welds. 2-shifting UT and radiography testing if
cycling will increase the any indications found.
potential for damage to more
highly stressed areas.
3 Downcomer Checks for corrosion and RVI A, C, D, E, F Infrequent
internal inspection debris accumulation in inspection, after
horizontal runs and at bottom UT testing if any indications chemical clean.
of downcomer vertical legs. found.
4 Downcomer Pipework adequately Check the integrity and settings A, C, D, E, F
supports supported. of the variable and constant
load supports.

Page 40 of 40