Final Report Tube Inspection HPB 721 (Louis

Dreyfus Company, Bandar Lampung)

Adhi Prihastomo (adhi.prihastomo@russindo.com)
10 October 2021

1 Introduction
1.1 Inspection Purpose
TUV-SUD has been inspected Boiler HPB 721 on 15, 16, and 17 September
2021, located at Plant Louis Dreyfus Company (LDC) Lampung. HPB 721
is a water tube boiler type with a pressure of 30 to 40 bar. The objective of
the boiler tube inspection are :

1. To conduct Surface and Volumetric examination of tube and header

using (MSD) Metal Stress, MECT (Magnetic Eddy Current Testing),
and Visual Inspection. 1

2. To conduct Thickness scanning using EMAT (Electro-Magnetic Ac-

coustic Transducer).

3. Calculate Corrosion Rate based on specification and actual measure-

ment data.

1.2 Specification
HPB 721 constructed in 85 wall tube diameter 2-inch and Two Headers (Top
and Bottom) diameter 6-inch. Wall tube height estimate 4800 mm from
Bottom Header and Top Header.
1
in accessible area

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2 Report
2.1 Visual Inspection
A visual inspection was conducted to assess the surface condition of the tube
and header. We ensure there is no surface crack, corrosion, dent, and other
surface flaws type may exist in the surface. Generally, the tube surface con-
dition is in good condition. Length of tube estimate 4800 mm from Bottom
to Top Header. The gap between tubes estimates a maximum of 1 mm.
Based on the visual inspection, all tubes were installed in the right po-
sition and gap between tube maximum 1 mm. For tube no. 23 and 24 as
shown below, there is heat insulation rope pinched between tubes. Rope size
estimate in 5 mm diameters.

Grid Mapping To facilitate inspection in all tubes and headers, we plan

grid mapping for tubes and headers. First, we determine tube number 1 to
tube number 85. For Vertical mapping, due to the tube length is 4800 mm,
so we divided it into 9 segments. Segment no. 1 to 8 with segment length
500 mm and last bottom segment no. 9 with segment length 800 mm.

Result

2.2 Metal Stress Detection Scanning

The objective of MSD scanning examining tube conditions and detection of
high-stress areas due to internal flaws. MSD using equipment IN-02 Metal
Stress Detector. Measurement process conducted in grid scanning method.
In the table below, we determined the scanning area for every tube. Metal
stress detector could take 3 segment data per scanning pass. Scanning direc-
tions have the same manner for all-tube, from below to above.
Results of Metal Stress Inspection consist of :
1. Stress scanning along tube
2. Indication of highly localized stress area

Result
1. Stress scanning is shown in paragraphs a), b), and c) below.
2. During measurement, the tube has been pressurizing about 50 bar, to
check pressure level and water leak of boiler HPB 721. In this pres-
surized condition, it’s ideal to conduct stress scanning. Stress scanning

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 performs first in the lower segment then the middle segment and the
last is the top segment.

3. The maximum magnetic field for all tubes at top segments ( no.1 to
no.3) is a maximum of 9,2 mT and on average 3,7 mT.

4. The maximum magnetic field for all tubes at middle segments (no.4 to
no.6) is a maximum of 8,7 mT and on average 4,3 mT.

5. The maximum magnetic field for all tubes at bottom segments (no.7
to no.9) is a maximum of 7,6 mT and on average 4 mT.

6. Based on full scanning in the front side tube area, it conclude that
there is no high indication of stress concentration. The signal appears
in uniform patterns for top segment, middle and bottom segment.

2.3 Magnetic Eddy Current Testing (MECT)

The objective of MECT is to examining tube conditions based on surface
and subsurface flaws. The MECT examination scanning areas were limited
to areas below the probe’s wedges. MECT conduct in all tube areas accessible
to inspection. Due to the possible access area on the front side of the boiler,
scanning was conducted on the half surface of the tube.
Results of MECT consist of :

1. Crack like flaws indication

2. Depth of crack (if flaws opened into surface)

3. Size of crack

4. The thickness of the surface layer, for this inspection, due to there is
no surface layer on tubes, it is will be ignored.

MECT Result :

1. MECT Scanning in all areas that are accessible for the probe to contact
into tube and header surface. All tube scanning results and indications
showed in the tables below.

2. There are several small indication below size 0,5 mm on :

ˆ Tube 6 (segment 1 and 2)

ˆ Tube 8 (segment 1)

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 ˆ Tube 29 (segment 2 and 3)
ˆ Tube 48 ( segment 2)
ˆ Tube 64 ( segment 3)
ˆ Tube 65 (segment 2)
ˆ Tube 66 (segment 2 and 3)
ˆ Tube 69, 70, and 71 (segment 2 and 3 respectively)
ˆ Tube 72 ( segment 1 and 3)
ˆ Tube 73 (segment 1 and 2)
ˆ Tube 82 (segment 2)
ˆ Tube 83 (segment 1 and 2)
ˆ Tube 84 (segment 1)
3. Visually, in all indication areas, not appears surface flaws or crack-like
indications.
4. Perform verification thickness measurement on indication using EMAT.
That area in good thickness condition, it is average in 3,0 to 3,1 mm.

2.4 Electro Magnetic Accoustic Transducer (EMAT)

The objective of EMAT is to measure the thickness of the tube and header
without using coupling between transducer and tube. Due to lack of surface
preparation on tube and header surface and short work duration, it’s difficult
to perform accurately thickness mapping use piezoelectric-based Ultrasonic
Thickness Gauge.

Thickness Verification Before conducting thickness mapping, verifica-

tion shall do to ensure EMAT measurement within margin error below 5%.
This step performs UT Thickness measurement on a random spot of the tube,
then performs EMAT measurement as the surface condition. UT Thickness
using DSM Go+ resulting in thickness 2,95 mm, then EMAT A1270 resulting
3,01 mm. Differences between both measurements are:
∆EM AT result − U T gaugeresult
M easurementerror = (1)
U T gaugeresult
3, 01 − 2, 95
M easurementError = (inmm) (2)
2, 95
M easurementError = 0, 02 (3)
M easurementError(percentage) = 2% (4)

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 Based on the deviation value between UT Thickness and EMAT, it is
confident to perform Thickness mapping on tube and header components
using EMAT.

Thickness Mapping Thickness mapping performs using EMAT on acces-

sible tube and header surface. To facilitate mapping, thickness measurement
conduct on a random spot. For tube number 1, 10, 20,30,40, 50, 60,70, and
80; perform EMAT Thickness Mapping for Segment 1 to segment 9. For Top
and Bottom Header, perform 10 spots thickness measurement respectively;
totally of 20 spots thickness at header pipes. Result of thickness mapping
shown in Table 8.
For segment no. 1, no. 5, and no. 9, perform thickness mapping in all
tube ( Tube no.1 to no. 85). Result of thickness mapping shown in Table 9.

3 Analysis
4 Conclusion