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Sample Inspection-Final Report2


SaskPower QE1 & QE2 Boiler Water Wall Tube Inspection

VertiScan? Inspection Report

Inspection Dates: Personnel:

April 22 to May 01, 2007 Dave Russell, Allen Russell, John Sprentz, Patrick McIntyre, Jarrod English

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Table of Contents
Table of Contents.................................................................................................................................................................2 Inspection Goals ..................................................................................................................................................................3 Boiler Specifications and tube numbering...........................................................................................................................4 Inspection Equipment ..........................................................................................................................................................5 Technique.............................................................................................................................................................................6 Calibration ............................................................................................................................................................................8 Executive Summary: Overview of Each Wall .....................................................................................................................9 Detailed Results: Color Wall Maps....................................................................................................................................10 Boiler #1 Wall Loss Indications Spreadsheet....................................................................................................................21 Boiler #2 Wall Loss Indications Spreadsheet....................................................................................................................23 Boiler #2 West Wall (Back) Ultrasonic Thickness Results Taken from Scaffold .............................................................24 Boiler #1 Ultrasonic Thickness Results near Datum Line ................................................................................................25 Boiler #2 Ultrasonic Thickness Results near Datum Line ................................................................................................28 Boiler #1 Features Spreadsheet Results ..........................................................................................................................30 Boiler #2 Features Spreadsheet Results ..........................................................................................................................34 Boiler Features Images......................................................................................................................................................37

2

Inspection Goals

The purpose of this inspection was to assess the condition of the water wall tubes in QE1 and QE2 boilers at the SaskPower, Saskatoon Power Station. 50% of the tubes in each boiler were to be inspected for a height of between 35’ and 59’ up from the bottom slope tubes. In areas where damage was detected, ultra-sonic readings were to be taken to confirm the minimum remaining wall and the nature of the damage mechanism. There were four issues that prevented the inspection goals from being completely attained: 1) Rods welded between the tubes on the back wall of QE2 were deteriorated such that they protruded from the walls above the crown of the tubes. These had the effect of preventing the crawler wheels from passing the obstruction. On this wall the maximum height reached was 26.44 feet (approximately 1631’-10” elevation) 2) Many tubes were bent and bowed due to the fact that there was no web between the tubes. In some cases, the crawler was placed on a tube that was bent in towards the centre of the boiler; however, these tubes often bent outwards further up, preventing the crawler from going further. 3) The only attachment point for the safety line was at the bottom of the superheater section (roughly equal to the bottom of the bullnose). This prevented the crawler from going any higher than this point on the side wall tubes. 4) In a very few cases there was a powdery scale on the tubes that accumulated on the crawler wheels. Once the accumulation exceeded ?” the crawler could proceed no further.

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Boiler Specifications and tube numbering

Boiler Manufacturer: Commissioned: Tube size: Nominal wall thickness:

Foster Wheeler 60 Mw 1959 (QE#2) and 1971 (QE#3) 3” tubes for all walls except the burner wall which is 2.5” 3” SA-178A at 0.165”, 2.25” SA-213-T11 at 0.150” - 0.180”, and 2.25” SA-213-TP321 at 0.150” From left to right for all walls when facing the wall inside the boiler A Laser level was used to locate the datum line (i.e. the zero-foot line for all scans). The side and back wall scans started approx 42” above the bottom slope tube bends at the first butt weld. The start-point for the burner wall was above the burners, with access from a scaffold. The datum line was measured with respect to the top burner center-line and all scans went up the wall from that elevation. For the divider walls, the same scaffold was used, and where possible the scans went up and down from that elevation. In certain locations the scaffold was too close to the divider wall to allow the VertiScan crawler to pass by. The divider walls in boiler #2 was only inspected from one side because the bends at the bottom of the divider wall were higher than could be reached to position the crawler above them.

Tube Numbering: Datum Line Position:

See the color maps for actual locations of the scans

4

Inspection Equipment

The inspection equipment was comprised of the following: 1) 2) 3) 4) 5) 6) TubeCAT? magnetic crawler with odometer VertiScan? inspection head for the inspection of 5 tubes simultaneously Ferroscope? 308, 16 channel RFT instrument Remote vision system 200’ umbilical data and power cable Dakota MVX digital ultrasonic instrument with 5MHz dual transducer.

The VertiScan System was developed over a period of 5 years by Russell NDE Systems Inc. with industry support. The latest generation incorporates improvements that make for a reliable, fieldproven inspection tool that can detect various service-induced defects and measure remaining wall thickness of the crown area of the tubes through scale up to ?” thick.

Fig-1 showing VertiScan System on wall. A safety rope and tag line are used to prevent the crawler from falling

5

Technique

Datum lines for all walls were marked for each boiler using a laser level. The tubes were scanned from this datum line upwards as far as the crawler could practically reach. Data was collected in both directions where possible. During the scans a video recording was made. This was useful in identifying “road blocks” such as the tack-welded rods between the tubes on the west wall of QE#2 (below the bull nose) which in some cases, prevented passage of the tool There were also some tubes that were bowed inwards, outwards or side-ways. Tubes were carefully selected to avoid the crawler traveling on bowed tubes as much as possible. Lastly, in a few instances on the divider walls, there was scale in excess of ?” thick which prevented some tubes from being scanned.

Fig-2 showing some bowed tubes

6

Fig-3 showing tack-welded and deformed rods between the tubes on the west wall of QE#2 (below the bull nose).

7

Calibration

Calibration of the VertiScan data was effected by taking ultrasonic thickness readings of all tubes at the datum line position. Generally these tubes were close to the nominal thickness of 0.165” for the back and side walls. Additional readings were taken at selected locations where the data showed wall loss. The elevations of the wall loss and the ultrasonic readings at these locations were correlated, and a calibration curve for the VertiScan was established. In several locations on the south wall of QE#1 there were blisters that had ruptured. These locations provided a calibration point representing 100% local wall loss.

Fig-4 showing blister and thinnest U.T. reading at centre of blister

8

Executive Summary: Overview of Each Wall

QE#1, East (back wall)
Significant internal pitting (10%-20% deep) detected above butt welds at 16.2’ from start of scan. This condition was detected on virtually all tubes scanned

QE#1, Divider Wall, North side
Indications of minor thermal damage. No significant defects detected

QE#1, Divider Wall, South side
Indications of minor thermal damage. No significant defects detected

QE#1, West (front, burner wall)
No significant defects detected

QE#1, North (left wall)
Indications of minor internal pitting (<10% deep) at various elevations above 15’ from start of scan.

QE#1, South (right wall)
Extensive area of blistering, internal pitting and pinhole leaks. Local areas of I.D. wall thinning to below 0.100” remaining wall. Internal pitting 20% to 35% deep.

QE#2, West (back wall)
Significant internal pitting detected starting at approximately 18 feet (above the datum). The maximum height achieved by the VertiScan was 26.44’ so additional scanning was done with ultrasonic equipment to a height of 32’ (elev 1637’13/4”). The tubes from about 42” above the bottom bend to the slope tubes had been replaced in the late 1990’s to approximately 20’ (elev 1625’-13/4”) and are in good condition. We recommend additional inspection up to the bull nose, and possibly including the bull nose, to determine the extent (maximum elevation) of the pitting.

QE#2, Divider Wall, South side
No significant defects detected

QE#2, East (front, burner wall)
Indications of minor thermal damage. No significant defects detected

QE#2, South (left wall)
Minor Internal pitting (10%-20% deep) at various elevations. Above this area there are several visible blisters and pinhole leaks (see photo in color map).

QE#2, North (right wall)
Minor internal pitting (10%-20% deep) on tubes 8-20 and 82-86 from 15’ to 17’ above the datum line.

9

Detailed Results: Color Wall Maps The following color maps are presented one per wall inspected and are identified according to the drawings supplied by SaskPower.

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11

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14

15

16

17

18

19

20

Boiler #1 Wall Loss Indications Spreadsheet

21

22

Boiler #2 Wall Loss Indications Spreadsheet

23

Boiler #2 West Wall (Back) Ultrasonic Thickness Results Taken from Scaffold

24

Boiler #1 Ultrasonic Thickness Results near Datum Line
North/Left Wall South/Right Wall

25

East/Back Wall

West/Front Wall

26

Divider Wall North/Left Wall

Divider Wall South/Right Wall

27

Boiler #2 Ultrasonic Thickness Results near Datum Line
North/Right Wall South/Left Wall East/Front Wall

28

West/Back Wall

Divider Wall North/Right Wall

Divider Wall South/Left Wall

29

Boiler #1 Features Spreadsheet Results
Wall East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East North North North North North North North North North North North North North North North North North North North North Tubes E3-7UP E3-7UP E3-7UP E13-17UP E13-17UP E26-30UP E26-30UP E26-30UP E33-37UP E33-37UP E33-37UP E41-45UP E41-45UP E41-45UP E41-45UP E53-57UP E53-57UP E53-57UP E53-57UP E63-67UP E63-67UP E73-77UP E73-77UP E84-88UP E84-88UP E84-88UP E84-88UP E91-95UP E91-95UP E91-95UP E101-105UP E101-105UP E101-105UP E111-115UP E111-115UP N3-7UP N3-7UP N3-7UP N3-7UP N3-7UP N7-11UP N7-11UP N7-11UP N13-17UP N13-17UP N13-17UP N20-24UP N20-24UP N20-24UP N20-24UP N28-32UP N28-32UP N28-32UP N28-32UP N28-32UP Channel Ch7 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f1 Ch12 f2 Ch12 f2 Ch12 f2 Ch11 f2 Ch12 f2 Ch12 f2 Ch12 f2 Ch12 f2 Ch6 f2 Ch12 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch6 f2 Ch12 f2 Ch10 f2 Ch12 f2 Ch10 f2 Ch12 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Data Index 881 1846 3754 1828 3794 915 1843 3799 894 1845 3770 849 1797 3707 4193 1809 1851 3733 3750 1833 3748 1832 3751 816 1801 3161 3729 865 1809 3722 1814 3589 3732 3705 4202 899 1866 3357 5377 9759 1825 3773 5389 1801 3754 5319 1835 3736 4107 5318 1863 3800 4202 5409 6541
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Comment Inspection port opening Buck stay Butt weld Buck stay Butt weld Inspection port opening Buck stay Butt weld Inspection port opening Buck stay Butt weld Inspection port opening Buck stay Butt weld Window weld Buck stay Buck stay Butt weld Butt weld Buck stay Butt weld Buck stay Butt weld Inspection port opening Buck stay Window weld Butt weld Inspection port opening Buck stay Butt weld Buck stay Window weld Butt weld Butt weld Window weld Inspection port Buck stay Inspection port Butt weld Inspection port Buck stay Butt weld Butt weld Buck stay Butt weld Butt weld Buck stay Butt weld Buck stay Butt weld Buck stay Butt weld Buck stay Butt weld Buck stay

Position (feet) 3.81 7.97 16.21 7.9 16.38 3.95 7.96 16.4 3.86 7.97 16.28 3.67 7.76 16.01 18.1 7.81 7.99 16.12 16.19 7.92 16.18 7.91 16.2 3.53 7.78 13.65 16.1 3.74 7.81 16.07 7.83 15.5 16.11 16 18.14 3.88 8.06 14.49 23.22 42.13 7.88 16.29 23.27 7.78 16.21 22.96 7.93 16.13 17.73 22.96 8.05 16.41 18.14 23.35 28.24

Wall North North North North North North North North North North North North North North North North North North North North North North North North North North North/Left North/Left North/Left North/Left North/Left North/Left North/Left North/Left North/Left North/Left North/Left North/Left North/Left North/Left North/Left North/Left South South South South South South South South South South South South South South South South South

Tubes N33-37UP N33-37UP N33-37UP N33-37UP N33-37UP N33-37UP N38-42UP N38-42UP N38-42UP N49-53UP N49-53UP N55-59UP N55-59UP N62-66UP N62-66UP N62-66UP N62-66UP N62-66UP N72-76UP N72-76UP N72-76UP N72-76UP N72-76UP N79-83UP N79-83UP N79-83UP NDW6-10UP NDW6-10UP NDW6-10UP NDW6-10UP NDW12-16UP NDW12-16UP NDW12-16UP NDW12-16UP NDW17-21UP NDW17-21UP NDW17-21UP NDW17-21UP NDW23-27UP NDW23-27UP NDW23-27UP NDW23-27UP S9-13UP S9-13UP S20-24UP S20-24UP S28-32UP S28-32UP S30-34UP S30-34UP S30-34UP S42-46UP S42-46UP S42-46UP S42-46UP S50-54UP S50-54UP S51-55UP S51-55UP

Channel Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch12 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch12 f2 Ch10 f2 Ch12 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch15 f2 Ch15 f2 Ch15 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch6 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch12 f2 Ch12 f2 Ch11 f2 Ch11 f2 Ch11 f2 Ch11 f2 Ch12 f2 Ch11 f2 Ch10 f2 Ch9 f1 Ch10 f2 Ch10 f2

Data Index 1790 1806 3787 4198 6512 6543 1783 3787 5365 3785 5397 3788 5385 1800 3789 4111 5347 6355 1858 3810 3810 5334 5334 1806 3759 3759 576 865 3179 5521 558 847 3164 5491 563 877 3193 5519 579 882 3205 5511 1809 3738 1784 3728 1814 3526 1791 3751 5360 1790 3731 4133 5342 1855 2368 1809 5216
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Comment Buck stay Buck stay Butt weld Buck stay Buck stay Buck stay Buck stay Butt weld Butt weld Butt weld Butt weld Butt weld Butt weld Buck stay Butt weld Buck stay Butt weld Window weld Buck stay Butt weld Butt weld Butt weld Butt weld Buck stay Butt weld Butt weld Butt weld Tube webbing Tube webbing Tube webbing Butt weld Tube webbing Tube webbing Tube webbing Butt weld Tube webbing Tube webbing Tube webbing Butt weld Tube webbing Tube webbing Tube webbing Buck stay Butt weld Buck stay Butt weld Buck stay Blisters Buck stay Butt weld Butt weld Buck stay Butt weld Buck stay Butt weld Buck stay Noise spike Buck stay Butt weld

Position (feet) 7.73 7.8 16.35 18.13 28.11 28.25 7.7 16.35 23.16 16.34 23.3 16.36 23.25 7.77 16.36 17.75 23.09 27.44 8.02 16.45 16.45 23.03 23.03 7.8 16.23 16.23 2.49 3.74 13.73 23.84 2.41 3.66 13.66 23.71 2.43 3.79 13.79 23.83 2.5 3.81 13.84 23.79 7.81 16.14 7.71 16.1 7.83 15.22 7.74 16.2 23.14 7.73 16.11 17.85 23.06 8.01 10.23 7.81 22.52

Wall South South South South South South South South South South South South South South South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right South/Right West West West West West West West West West West West West West West

Tubes S62-66UP S62-66UP S62-66UP S62-66UP S72-76UP S72-76UP S72-76UP S79-83UP S79-83UP S79-83UP S87-91UP S87-91UP S87-91UP S87-91UP SDW1-5UP SDW1-5UP SDW1-5UP SDW1-5UP SDW1-5UP SDW1-5UP SDW1-5UP SDW9-13UP SDW9-13UP SDW9-13UP SDW9-13UP SDW9-13UP SDW9-13UP SDW17-21UP SDW17-21UP SDW17-21UP SDW17-21UP SDW17-21UP SDW24-28UP SDW24-28UP SDW24-28UP SDW24-28UP SDW24-28UP SDW31-35UP SDW31-35UP SDW31-35UP SDW31-35UP SDW31-35UP SDW34-38UP SDW34-38UP SDW34-38UP W78-82UP W78-82UP W78-82UP W78-82UP W78-82UP W78-82UP W85-89UP W85-89UP W85-89UP W85-89UP W85-89UP W85-89UP W93-97UP W93-97UP

Channel Ch10 f2 Ch10 f2 Ch12 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch15 f2 Ch15 f2 Ch15 f2 Ch15 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch8 f2 Ch8 f2 Ch11 f2 Ch11 f2 Ch11 f2 Ch11 f2 Ch11 f2 Ch11 f2 Ch11 f2 Ch11 f2

Data Index 1837 3741 4160 5362 1815 3734 5317 1788 3760 5406 818 3294 3720 5322 162 388 2719 4726 5066 7332 9695 120 2353 4391 4706 6998 9321 1999 3984 4274 6591 8924 1860 3849 4161 6476 8819 1870 3869 4168 6481 8822 1881 3874 4194 208 615 2233 3860 4727 5046 213 603 2227 3744 4685 5040 193 589
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Comment Buck stay Butt weld Buck stay Butt weld Buck stay Butt weld Butt weld Buck stay Butt weld Butt weld Inspection port opening Inspection port opening Butt weld Butt weld Butt weld Tube webbing Tube webbing Butt weld Tube webbing Tube webbing Tube webbing Tube webbing Tube webbing Butt weld Tube webbing Tube webbing Tube webbing Tube webbing Butt weld Tube webbing Tube webbing Tube webbing Tube webbing Butt weld Tube webbing Tube webbing Tube webbing Tube webbing Butt weld Tube webbing Tube webbing Tube webbing Tube webbing Butt weld Tube webbing Butt weld Butt weld Buck stay Buck stay Window weld Window weld Butt weld Buck stay Buck stay Buck stay Window weld Window weld Butt weld Buck stay

Position (feet) 7.93 16.15 17.96 23.15 7.84 16.12 22.96 7.72 16.23 23.34 3.54 14.22 16.06 22.98 0.7 1.68 11.74 20.4 21.87 31.65 41.85 0.52 10.16 18.96 20.32 30.21 40.24 8.63 17.2 18.45 28.46 38.53 8.03 16.62 17.97 27.96 38.07 8.08 16.71 18 27.98 38.09 8.12 16.73 18.11 0.9 2.66 9.64 16.67 20.41 21.79 0.92 2.61 9.62 16.17 20.23 21.76 0.84 2.55

Wall West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West West

Tubes W93-97UP W93-97UP W93-97UP W93-97UP W101-105UP W101-105UP W101-105UP W101-105UP W101-105UP W103-107UP W103-107UP W103-107UP W111-115UP W111-115UP W111-115UP W111-115UP W111-115UP W111-115UP W111-115UP W111-115UP W118-122UP W118-122UP W118-122UP W118-122UP W118-122UP W118-122UP W122-126UP W122-126UP W122-126UP W122-126UP W122-126UP W122-126UP W122-126UP W122-126UP W130-134UP W130-134UP W130-134UP W130-134UP W130-134UP W130-134UP W133-137UP W133-137UP W133-137UP W133-137UP W138-142UP W138-142UP W138-142UP W138-142UP W138-142UP W144-148UP W144-148UP W144-148UP W144-148UP

Channel Ch11 f2 Ch11 f2 Ch11 f2 Ch11 f2 Ch11 f2 Ch11 f2 Ch8 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch6 f2 Ch6 f2 Ch6 f2 Ch12 f2 Ch8 f2 Ch12 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch7 f2 Ch7 f2 Ch7 f2 Ch7 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch8 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2

Data Index 2215 3797 4702 5036 197 555 727 2175 3808 210 612 2204 164 569 1361 2196 3807 4626 4711 5030 171 513 2149 3752 4680 5046 144 479 2099 2833 2969 3743 4517 4789 138 228 485 719 2128 3764 109 515 2127 3746 174 504 2165 3760 4785 127 515 2160 3745

Comment Buck stay Buck stay Window weld Window weld Butt weld Buck stay Butt weld Buck stay Buck stay Butt weld Buck stay Buck stay Butt weld Buck stay Soot blower Buck stay Buck stay Window weld Window weld Window weld Butt weld Buck stay Buck stay Buck stay Window weld Window weld Butt weld Buck stay Buck stay Tack weld Window weld Buck stay Tack weld Butt weld Butt weld Liftoff Buck stay Butt weld Buck stay Buck stay Butt weld Buck stay Buck stay Buck stay Butt weld Buck stay Buck stay Buck stay Butt weld Butt weld Buck stay Buck stay Buck stay

Position (feet) 9.57 16.39 20.3 21.74 0.85 2.4 3.14 9.39 16.44 0.91 2.65 9.52 0.71 2.46 5.88 9.48 16.44 19.97 20.34 21.72 0.74 2.22 9.28 16.2 20.21 21.79 0.63 2.07 9.07 12.23 12.82 16.16 19.5 20.68 0.6 0.99 2.1 3.11 9.19 16.25 0.47 2.23 9.19 16.17 0.76 2.18 9.35 16.23 20.66 0.55 2.23 9.33 16.17

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Boiler #2 Features Spreadsheet Results
Wall East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East East North North North North North North North North North North North North North Tubes E78-82UP E78-82UP E78-82UP E78-82UP E78-82UP E78-82UP E86-90UP E86-90UP E86-90UP E86-90UP E86-90UP E86-90UP E86-90UP E86-90UP E86-90UP E86-90UP E96-100UP E96-100UP E96-100UP E96-100UP E102-106UP E102-106UP E102-106UP E102-106UP E111-115UP E111-115UP E111-115UP E111-115UP E111-115UP E119-123UP E119-123UP E119-123UP E119-123UP E119-123UP E127-131UP E127-131UP E127-131UP E127-131UP E136-140UP E136-140UP E136-140UP E136-140UP E136-140UP N8-12DN N8-12UP N8-12UP N8-12UP N8-12UP N16-20UP N16-20UP N16-20UP N16-20UP N16-20UP N24-28UP N24-28UP N24-28UP Channel Ch12 f2 Ch10 f2 Ch11 f1 Ch10 f2 Ch10 f2 Ch12 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch13 f2 Ch2 f1 Ch10 f2 Ch10 f2 Ch12 f2 Ch12 f2 Ch6 f2 Ch10 f2 Ch11 f2 Ch11 f2 Ch8 f2 Ch10 f2 Ch10 f2 Data Index 506 778 1079 2415 4070 5146 477 486 798 798 2432 2432 4056 4056 5120 5129 460 778 2423 4047 465 784 2431 4065 467 784 2436 4051 5115 454 768 2419 4052 5091 452 775 2441 4032 459 785 2413 4032 5084 162 2316 225 1882 4092 315 657 1988 3749 3881 353 1992 2008
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Comment Butt weld Buck stay Tube stabilizer? Buck stay Buck stay Butt weld Butt weld Butt weld Buck stay Buck stay Buck stay Buck stay Buck stay Buck stay Butt weld Butt weld Butt weld Buck stay Buck stay Buck stay Butt weld Buck stay Buck stay Buck stay Butt weld Buck stay Buck stay Buck stay Butt weld Butt weld Buck stay Buck stay Buck stay Butt weld Butt weld Buck stay Buck stay Buck stay Butt weld Buck stay Buck stay Buck stay Butt weld Odometer came off when crawler turned Start is 6.25 inches above base line Butt weld Buck stay Butt weld Butt weld Noise spike (all channels) Buck stay Butt weld Window weld Butt weld Buck stay Buck stay

Position (feet) 2.19 3.36 4.66 10.43 17.57 22.22 2.06 2.1 3.45 3.45 10.5 10.5 17.5 17.5 22.1 22.14 2 3.36 10.46 17.47 2.01 3.39 10.5 17.55 2.02 3.39 10.52 17.49 22.08 1.96 3.32 10.45 17.5 21.98 1.96 3.35 10.54 17.41 1.99 3.39 10.42 17.41 21.95 0.7 0.24 0.98 8.13 17.67 1.36 2.84 8.59 16.19 16.76 1.53 8.6 8.67

Wall North North North North North North North North North North North North South South South South South South South South South South South South South South South South South South South South/Left South/Left South/Left South/Left South/Left South/Left South/Left South/Left South/Left South/Left South/Left South/Left West West West West West West West West West West West West West West West West

Tubes N24-28UP N24-28UP N24-28UP N29-33UP N29-33UP N29-33UP N39-43UP N39-43UP N39-43UP N39-43UP N54-58UP N82-86UP S05-09UP S05-09UP S05-09UP S05-09UP S05-09UP S05-09UP S09-13DN S09-13UP S19-23UP S28-32UP S37-41UP S45-49UP S55-59UP S55-59UP S68-72UP S68-72UP S77-81UP S77-81UP S77-81UP SDW18-22UP SDW18-22UP SDWB18-22DN SDWB18-22DN SDWB18-22DN SDWB18-22DN SDWB18-22DN SDW27-31UP SDW27-31UP SDW38-42UP SDW38-42UP SDW38-42UP W3-7UP W3-7UP W3-7UP W8-12UP W8-12UP W13-17UP W28-32UP W28-32UP W28-32UP W33-37UP W33-37UP W33-37UP W43-47UP W43-47UP W52-56UP W66-70UP

Channel Ch8 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f1 Ch10 f2 Ch10 f2 Ch6 f1 Ch10 f2 Ch7 f2 Ch6 f2 Ch11 f2 Ch7 f2 Ch7 f2 Ch11 f2 Ch6 f2 Ch11 f2 Ch11 f2 Ch10 f2 Ch14 f2 Ch10 f2 Ch10 f2 Ch11 f2 Ch10 f2 Ch9 f2 Ch10 f2 Ch12 f2 Ch10 f2 Ch10 f2 Ch10 f2 Ch9 f1 Ch10 f1 Ch10 f1 Ch12 f1 Ch9 f1 Ch10 f2 Ch10 f2 Ch10 f2 Ch10 f1 Ch10 f2 Ch10 f2 Ch12 f1 Ch10 f2 Ch10 f2 Ch9 f2 Ch9 f2 Ch10 f2 Ch11 f1 Ch11 f1 Ch15 f2 Ch15 f2 Ch10 f2 Ch11 f1 Ch10 f2 Ch10 f2 Ch10 f2

Data Index 3808 5497 6607 356 3839 5542 355 744 3803 5522 428 5540 854 1234 1733 2777 3204 5601 8292 5588 5480 5485 432 3761 398 3447 371 3817 387 3799 4076 1009 5547 1634 2273 2412 2438 2577 1018 5546 1007 1025 5551 56 252 1008 3815 4217 3812 3833 4719 5638 940 1275 3810 52 3812 3824 3815

Comment Butt weld Butt weld Buck stay Butt weld Butt weld Butt weld Butt weld Liftoff Butt weld Butt weld Noise spike Butt weld Inspection port opening (Tube 4) Inspection port opening (Tube 4) Butt weld Inspection port opening (Tube 4) Inspection port opening (Tube 4) Butt weld Center tube causing liftoff on tubes 9 and 10 Butt weld Butt weld Butt weld Butt weld Butt weld Butt weld Butt weld Butt weld Butt weld Butt weld Butt weld Butt weld Butt weld Tube webbing Noise spike Noise spike Noise spike Noise spike Noise spike Butt weld Tube webbing Butt weld Tube webbing Tube webbing Butt weld Butt weld Butt weld Butt weld Butt weld Butt weld Butt weld Window weld Deformed bar caused crawler to fall Inspection port opening Inspection port opening Butt weld First weld above sloped tubes (Datum line) Butt weld Butt weld Butt weld
35

Position (feet) 16.44 23.73 28.52 1.54 16.58 23.93 1.54 3.22 16.42 23.84 1.85 23.92 3.69 5.33 7.49 11.99 13.83 24.18 35.8 24.13 23.99 23.8 1.87 16.24 1.72 14.88 1.61 16.48 1.67 16.4 17.6 3.5 23.95 7.06 9.82 10.42 10.53 11.13 3.5 23.94 3.5 4.43 23.97 0.24 1.09 4.35 16.46 18.1 16.46 16.55 20.4 24.34 4.06 5.51 16.45 0.22 16.46 16.51 16.47

Wall West West West West West West West West West West West West West West West West West

Tubes W66-70UP W73-77UP W84-88UP W84-88UP W84-88UP W84-88UP W91-95UP W91-95UP W91-95UP W99-103UP W99-103UP W99-103UP W108-112UP W108-112UP W114-118UP W114-118UP W114-118UP

Channel Ch10 f2 Ch10 f2 Ch12 f2 Ch12 f2 Ch12 f2 Ch10 f2 Ch15 f2 Ch15 f2 Ch11 f2 Ch1 f1 Ch6 f2 Ch10 f2 Ch10 f2 Ch14 f2 Ch14 f2 Ch14 f2 Ch11 f2

Data Index 3849 3843 920 1251 3802 5274 885 1230 3786 826 1263 3807 3781 4299 903 1239 3833

Comment Butt weld Butt weld Inspection port opening (Tube 83) Inspection port opening (Tube 83) Butt weld Odometer checked 5ft Inspection port opening (Tube 96) Inspection port opening (Tube 96) Butt weld Inspection port opening Inspection port opening Butt weld Butt weld Window weld Inspection port opening (Tube 119) Inspection port opening (Tube 119) Butt weld

Position (feet) 16.62 16.59 3.97 5.4 16.41 22.77 3.82 5.31 16.35 3.57 5.46 16.44 16.33 18.56 3.9 5.35 16.55

36

Boiler Features Images

The following images display the features found in the boiler and data collected. Features were reported if they had an influence on the VertiScan data and can be found in the Features Spreadsheet Results tables.

Figure 5 - Image showing two types of soot blowers.

Figure 6 - Inspection doors from the back and right walls.

37

Figure 7 - On the left, butt welds and tube webbing (found on the divider walls). On the right, an example of window welds.

Figure 8 - Image showing bent and broken rods on the back wall preventing the VertiScan from reaching maximum height.

38

Figure 9 - Visible blisters as seen from the VertiScan camera. The lower right blister has a leak.

In Boiler #2 on the east wall, a short indication of wall thickening was picked up. After reviewing the data, it appears that there is possibly some form of tube stabilizer behind the tube, as seen in the image below.

Figure 10 - Image of possible tube stabilizer behind tube 80.

39

Figure 11 - VertiScan data displaying some reported features.
40


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