Reference: Work Order Number – 10266

Report Number: OMIFCO/MDD&G/10266

Scope of Work: Eddy Current Testing, Remote Field Electromagnetic Testing and IRIS
inspection of Heat Exchangers like RG Boiler, MP Decomposer,
LP Decomposer, LP Decomposer, GV Re-boiler, etc.

ECT REPORT (11-E-103 LP DECOMPOSER)

Modern Diamond Drop and Gulachi LLC

CR: 1314824
Address: 500, City Season Building, Al Khuwair, Muscat, PO Box 404,
PC 112, Sultanate of Oman
Email: info@mddoman.com, http://www.mddoman.com

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Modern Diamond Drop and Gulachi LLC
 Oman India Fertilizer Company
Sur, Oman

Final Report

(22-02-2023 to 02-03-2023)

Prepared By Reviewed By Accepted By

Ayush Tiwari Amitendra Tripathi Ankit Niranjan

MDD&G MDD&G OMIFCO

Modern Diamond Drop and Gulachi LLC

Muscat, Sultanate of Oman
Email: info@mddoman.com, http://www.mddoman.com

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Modern Diamond Drop and Gulachi LLC
 Modern Diamond Drop and Gulachi LLC Report No: OMIFCO/MDD&G/10266
Address: 500 City Season Building, Al Khuwair Duration of Test: 28/02/2023
PO Box 404, PC 112, Muscat Date of Report: 02-03-2023

FINAL REPORT – EDDY CURRENT TESTING OF 11 – E – 103

CONTACT
a. Registered Name Modern Diamond Drop and Gulachi LLC

b. Registered Address 500, City Season Building, Al Khuwair, Muscat,

PO Box 404, PC 112, Sultanate of Oman

c. Contact Person Mr. Abhay Tripathi

Director
M: +968 90905506
E: abhay@mddoman.com

d. Official Website www.mddoman.com

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Modern Diamond Drop and Gulachi LLC
 Modern Diamond Drop and Gulachi LLC Report No: OMIFCO/MDD&G/10266
Address: 500 City Season Building, Al Khuwair Duration of Test: 28/02/2023
PO Box 404, PC 112, Muscat Date of Report: 02-03-2023

FINAL REPORT – EDDY CURRENT TESTING OF 11 – E – 103

PREFACE
Modern Diamond Drop and Gulachi LLC is a Muscat based NDT Inspection,
Testing and Industrial Solution Service providing company. We are an
Omani company incorporated in 2018.

During the February 2023 Shutdown we carried out

Eddy Current Testing of LP Decomposer 11-E-103
at Oman India Fertilizer Company, Sur, Oman.

Modern Diamond Drop and Gulachi LLC inspection

team carried out the job during
22nd February 2023 to 02nd March 2023.

Our NDT Personnel, as per the guidelines given

in ASME codes and standards, and using the
latest techniques evaluated, analyzed the NDT
testing, their results. All the testing, evaluation,
interpretation, conclusion and recommendation
are listed in this final report.

Modern Diamond Drop and Gulachi LLC expressed their sincere thanks to
Oman India Fertilizer Company, for the support, guidance and cooperation
extended by them for successful completion of this Eddy Current Tube
Inspection Job.

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Modern Diamond Drop and Gulachi LLC
 Modern Diamond Drop and Gulachi LLC Report No: OMIFCO/MDD&G/10266
Address: 500 City Season Building, Al Khuwair Duration of Test: 28/02/2023
PO Box 404, PC 112, Muscat Date of Report: 02-03-2023

FINAL REPORT – EDDY CURRENT TESTING OF 11 – E – 103

TABLE OF CONTENT

Executive Summary…………………………………………………………………………………………………………….Page No. 06

1. Introduction…………………………….….………………………………………………………….………………………Page No. 07

2. Technical details of LP Decomposer…………………………………………………..……………………………Page No. 07

3. ECT Technique…………………………………………………………………..………………………………………..….Page No. 07

4. Reference Documents…………………………………………………………..………………………….…………….Page No. 08

5. ECT Personnel…………………………………………………………………………………………..…………………….Page No. 08

6. ECT Equipment and Accessories…………………………………………………………………………….……….Page No. 08

7. ECT Calibration Tube………………………………………………………………………..…………………………….Page No. 09

8. ECT Procedure…………………………………………………………………………….………………………………….Page No. 09

9. Extent of testing…………………………………………………………………………………………….……………….Page No. 10

10. ECT Calibration Record………………………………………………………………………………………………….Page No. 10

11. Scanned tube and tube map…………………………………………………………………………………………Page No. 11

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Modern Diamond Drop and Gulachi LLC
 Modern Diamond Drop and Gulachi LLC Report No: OMIFCO/MDD&G/10266
Address: 500 City Season Building, Al Khuwair Duration of Test: 28/02/2023
PO Box 404, PC 112, Muscat Date of Report: 02-03-2023

FINAL REPORT – EDDY CURRENT TESTING OF 11 – E – 103

Executive Summary

Eddy current testing of LP Decomposer 11-E-103 currently operational in Urea -I unit was
conducted in the month of February 2023.

Total of 844 Straight Tubes are installed out of which87 Straight tubes wereexamined as per the
instructions of OMIFCO E.I.C.

During visual inspection of tube-sheet face, tubes were found dry condition but the tubes had
some amount of scaling present which led to using a smaller diameter probe.

One important aspect to be kept into mind that while looking in to ID & OD wall thickness
signals, ID wall thinning is represented between 00 to 400 and OD wall thinning is represented
above 400. So, measurement accuracy on ID side is less and OD side is more. Since through hole
signal is set at 400, a minor variation in phase angle may represent ID signal as OD signal and
vice versa.

Following is the summary of wall thinning observations:

Observation Summary

% WALL THINNING NUMBER OF TUBES IN TOP HALF

0%-19% 87
20%–29% 0
30%– 39% 0
40%– 49% 0
50%– 59% 0
60% AND ABOVE 0
ALREADY PLUGGED 0

 Total of 844 Straight Tubes are tubes installed.

 87 Straight Tubes were examined.
 None of the tubes reflected indications of wall loss greater than 19% of nominal wall
thickness

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Modern Diamond Drop and Gulachi LLC
 Modern Diamond Drop and Gulachi LLC Report No: OMIFCO/MDD&G/10266
Address: 500 City Season Building, Al Khuwair Duration of Test: 28/02/2023
PO Box 404, PC 112, Muscat Date of Report: 02-03-2023

FINAL REPORT – EDDY CURRENT TESTING OF 11 – E – 103

1. INTRODUCTION: Eddy Current Testing of LP Decomposer 11-E-103 operating in unit Urea-I at

Oman India Fertilizers Company, Sur, Sultanate of Oman was carried out during the Shutdown
of February 2023. This report gives information about testing technique, inspection coverage,
observations and remark on observations.

2. TECHNICAL DETAILS OF UREA STRIPPER

Heat Exchanger Identification 11-E-103

Operational Year -
Previous ECT Inspection -
Orientation Vertical
Tube Dimensions 38.1mmO.D
x1.65mmThickness
M.O.C SS 316 L
Number of Tubes 844
Type of tube Straight Tubes
Tube Length 6165 mm
Length Scanned Only Straight Portion

3. ECT TECHNIQUE: Eddy Current Testing is based on the principle of Electromagnetic

Induction in conductive materials. The technique is based on interaction, which occurs
between a coil, energized with alternating current and the eddy current induced in to object
being examined. The testing of tubes is performed with a bobbin coil that produces an
electromagnetic field in the tube. When the probe is pulled across a discontinuity, the
electromagnetic field is distorted. This distortion in magnetic field changes the coil impedance
that is related to the discontinuity and finally changes in the magnitude of the induced voltage
or current in a nearby pickup coil.

Data Acquisition and Analysis: Dedicated software is used for data acquisition, data analysis
and display. The data acquisition module collects the tube data at a given sample rate. The
menu driven, user-oriented program provides for real-time display of phase, amplitude and
probe position in the tube. The data analysis and display module contain the calibration curves
for wall thinning, volume losses, pits, vibration / fretwear and correlates the calibration
standard in formation with the actual plant data for flaw sizing and evaluation.

Capabilities and Limitations: The technique is effective for detecting pitting, surface erosion,
erosion damage, localized wall loss and other small defects on the free portion of tube and

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Modern Diamond Drop and Gulachi LLC
 Modern Diamond Drop and Gulachi LLC Report No: OMIFCO/MDD&G/10266
Address: 500 City Season Building, Al Khuwair Duration of Test: 28/02/2023
PO Box 404, PC 112, Muscat Date of Report: 02-03-2023

FINAL REPORT – EDDY CURRENT TESTING OF 11 – E – 103

under tube support plate. The technique is less effective for thin defects in circumferential
orientation. Any defect causing thickness reduction more than 20% of wall thickness can be
easily detected. Test System is also calibrated with 1.3 mm diameter through hole and any
opening of such order can be easily detected however, minute pin holes may go unnoticed.

4. REFERENCE DOCUMENT:
ASME Boiler and Pressure Vessel Code Section-V, Article-8 UREA STRIPPER Drawing
ECT Equipment Operating Manual

5. ECT PERSONNEL:

a. Ayush Tiwari ECT Level – II

b. Jayprakash Rawat ECT Level – II

6. ECT EQUIPMENT AND ACCESSORIES:

a. Eddy Current Equipment: Make- OLYMPUS, Model: MS5800: It is a powerful leading-
edge multi-frequency multichannel eddy current test system ideally suited for manual
or automatic in-service inspection of steam generator / heat exchanger tubes. Up to
eight frequencies can be used simultaneously for testing with up to 16 differential and
absolute channels at very high sampling rates. Software includes data acquisition,
storage, automatic analysis, tube-sheet mapper, history compare and reporting.
b. Dedicated software is used for data acquisition, data analysis and display. The data
acquisition module collects the tube data at a given sample rate. The menu driven,
user-oriented program provides for real-time display of phase, amplitude and probe
position in the tube. The row and column of the tube, probe speed and other book
keeping details are also handled by the data acquisition.
c. The data analysis and display module contain the calibration curves for wall thinning,
volume losses, pits, vibration/fret wear and correlates the calibration standard
information with the actual plant data for flaw sizing and evaluation.

d. Manually driven Differential probe operating in both Differential and Absolute mode
suiting the ID of the Tube.

e. Laptop computer loaded with software for data acquisitions, signal processing and analysis.

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Modern Diamond Drop and Gulachi LLC
 Modern Diamond Drop and Gulachi LLC Report No: OMIFCO/MDD&G/10266
Address: 500 City Season Building, Al Khuwair Duration of Test: 28/02/2023
PO Box 404, PC 112, Muscat Date of Report: 02-03-2023

FINAL REPORT – EDDY CURRENT TESTING OF 11 – E – 103

7. ECT CALIBRATION TUBE:

CalibrationStandardswerefabricatedonfreshtubeofsamedimensionsandmaterial.Followingarti
ficialdiscontinuities were introduced:
1. 100% Through Wall Hole 1.7mm ø 1 No.
2. 80% Flat Bottom Hole 2.0mmø 1 No.
3. 60% Flat Bottom Hole 2.8mm ø 1 No.
4. 40% Flat Bottom Hole 4.8mm ø 1 No.
5. 20% Flat Bottom Hole 3.2mm ø 4Nos. 900 Apart
6. 20% OD Groove 2.0mmWidth 3600
7. 10% ID Groove 1.6mm Width 3600

8. ECT PROCEDURE:
Test Parameters: Test frequency is selected as per tube material and tube wall thickness.
Gain and phase is adjusted to obtain signals of required amplitude and separation between
Id and OD signals as shown in below figure. Calibration tube with reference flaws is used to
establish sensitivity and amplification required. Testing of Tube: The probe is inserted into
the tube till it reaches bottom side tube sheet. The probe is then gradually withdrawn from
the tube at a steady speed and the data is collected on a hard disk. The processing of the
data occurs in real-time. Impedance plane signal and corresponding x-y plot is stored. The
Data is further analyzed using Data Analysis Software and Calibration Curve obtained from
Calibration tubes.

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Modern Diamond Drop and Gulachi LLC
 Modern Diamond Drop and Gulachi LLC Report No: OMIFCO/MDD&G/10266
Address: 500 City Season Building, Al Khuwair Duration of Test: 28/02/2023
PO Box 404, PC 112, Muscat Date of Report: 02-03-2023

FINAL REPORT – EDDY CURRENT TESTING OF 11 – E – 103

9. EXTENT OF TESTING: only 93 Tubes colored in purple have been scanned and analyzed.

10. ECT CALIBRATION RECORD: ECT calibration parameter and calibration record are described below:

ECTPROBE
Probe Style Number Shaft Length Extension Cable
Differential/Absolute:18mm 15M NA

ECTEQUIPMENT
Make & Model Serial No. Calibration Date
OLYMPUS, MS5800 1131736 01/08/2022

Parameters Channel-1 Channel-2 Mixer-1

Frequency(KHz) 60kHz 30KHz Ch-1&Ch2
Gain(dB) 46Db 49dB 0.0Db
Phase(Degree) 60 212 87

Reference Channel-1 Channel-2 Mixer-1

Flaw Phase Amplitude Phase Amplitude Phase Amplitude
100%Hole 40 1.00 40 1.00 40 1.00
80%FBH 59 0.92 54 0.85 53 0.83
60%FBH 77 1.20 64 1.17 62 1.11
40%FBH 89 1.40 80 1.31 83 1.32
20%FBH 109 1.45 102 1.35 215 1.39
10%ID 02 1.84 10 1.57 09 1.62

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Modern Diamond Drop and Gulachi LLC
 Modern Diamond Drop and Gulachi LLC Report No: OMIFCO/MDD&G/10266
Address: 500 City Season Building, Al Khuwair Duration of Test: 28/02/2023
PO Box 404, PC 112, Muscat Date of Report: 02-03-2023

FINAL REPORT – EDDY CURRENT TESTING OF 11 – E – 103

ROW-1 TUBE 1 ROW-1 TUBE 8

ROW-35 TUBE 1 ROW-35 TUBE 8

 PLEASE REFER COLOUR CODES MENTIONED.

 TUBE COUNTING MARKED ON TUBE MAP ABOVE.
 ROW COUNTING FROM TOP TO BOTTOM
 TUBE COUNTING FROM LEFT TO RIGHT
 SCANNED TUBES WITH WALL LOSS WITHIN 0-19% ARE MARKED IN PURPEL

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Modern Diamond Drop and Gulachi LLC