Wor|d Lnergy Counc||

M|n|stry Cf L|ectr|c|ty Lnergy

Lgypt|an no|d|ng Company Ior L|ectr|c|ty
Upper Lgypt L|ectr|c|ty roduct|on Company
-,-' ,~- -,;|-=- --;--' ~-'
8oller llfe assessmenL

LNG InIM LL Snn@

Contents Contents
I. Thc puvposc oI boi!cv !iIc asscssmcnt
i. LiIc Eva!uation by Inspcction
. Pvcpavations Iov Inspcction
. Data vcquivcmcnt
. Inspcction oI high pvcssuvc pavts.
. Samp!c tubc inspcction.
. Visua! inspcction Iov othcv pavts oI boi!cv .
. Watcv qua!ity suvvcy.
. Visua! Inspcction Iov aux Equipmcnt
Io. high pvcssuvc pavts Inspcction dctai!s
@e urpose of boller llfe assessmenL
O Evaluaie ile pieseni siaie and ile condiiion of ile boilei componenis in oidei
To coniinue siable and ieliable boilei opeiaiion
O Evaluaie ile iemaining life foi Supeileaiei and Releaiei by meialluigical
inspeciion
O Evaluaiion of cieep life and fuiuie inspeciion scleme by meialluigical
inspeciion foi waiei wall, economizei, Supeileaiei and Releaiei iubes
O Evaluaiion degiee of cieep damage foi Supeileaiei and Releaiei by laidness
iesi
O Evaluaie ile iemaining life based on iliclness Measuiemeni foi waiei wall,
O Evaluaie ile iemaining life based on iliclness ilinning foi economizei due io
low Tempeiaiuie Coiiosion,
O Evaluaie ile iemaining life based on iliclness ilinning foi Supeileaiei and
Releaiei iubes due io ligl Tempeiaiuie Coiiosion
O Confiim ile cause of ile innei scale geneiaiion
O Evaluaie ile iemaining life based on clecl of meial siiuciuie ,innei scale ,eic
foi sample iube
lfe LvaluaLlon by lnspecLlon
RE DM CS ENOMENON E EVTON NSECTON TEM
O CREE OClogging wiil
foieign maieiial
ODeposiiion and
giowil of scale on
nnei suiface
Oong-ieim siiess
OSwelling
OMeial siiuciuie
clange
OOuiside diameiei and
iliclness measuiemeni
OMeialluigical
inspeciion
OMeialluigical inspeciion foi S, R
leadei,
OMeialluigical inspeciion and NDT
(T) foi main sieam pipe line and ligl
iempeiaiuie R pipe
OTE OCycle ileimal
siiess
Oiowil of ciacl OSiiess analysis
OSuiface ciacl
inspeciion (T,MT)
ONDE (T, MT) of spacei welded foi S
and R Tube
OCORROSON
TE
OCyclic ileimal
siiess undei
coiiosive
enviionmeni
Onieiaciion of
coiiosion and
faiigue
Oliiasonic iesi
OSample iube inspeciion
OSample iube inspeciion foi S, R
and waiei wall
OClecl of Buinei Nozzle and Wind Box
Dampei
OCORROSON
OEROSON
Oigl iemp
coiiosion
Oow iemp
coiiosion
Osl eiosion
OTliclness
ilinning
Onnual iliclness
measuiemeni
O measuiemeni of iube iliclness foi S
,R, Waiei Wall and Eco by T
OSieam dium
OBoilei aux
OEco angei iube by endoscope, eic
reparaLlons for lnspecLlon
O cIovc inspcction
O Supeileaiei, ieleaiei, economizei and waiei wall cleaning
O ii leaiei wasling
O Scaffolding
O Removal of insulaiion
O Open man loles, inspeciion loles, flanges eic
O Duving inspcction
O Suiface piepaiaiion of inspeciion paiis
O Suiface finisling (giinding) of inspeciion paiis
O nsiiumeni of appaiaius of inspeciion
O Cuiiing iubes
O Welding iubes
O atcvia! vcquivcmcnt
O New iubes
O Man lole pacling
O insulaiion
O Pcviod oI inspcction
O Two weels
ata requ|rement
O oi!cv vcIcvcncc data
O Sieam iempeiaiuie
o
c
O Maximum Sieam flow Ton]li
O Boilei design piessuie Kgm]cm
:
O eed waiei iemp
o
c
O Releaied inlei sieam iempeiaiuie
o
c
O Releaied ouilei sieam iempeiaiuie
o
c
O Releaiei design piessuie Kgm]cm
:
O Kind of fuel as, Oil
O unctiona! inspcction with boi!cv in opcvation
O Colleciion of diawings and main ieclnical daia
O Recoiding of aciual opeiaiing and funciional daia ai diffeieni loads and
condiiions ai MCR and Veiificaiion of ile opeiaiion of ile boilei
O Colleciion of daia ielevani io ile ileimal lisioiy and inieiveniions ,if any
made on ile boilei duiing lis opeiaiion life
lnspecLlon of lg pressure parLs
O Dcstvuctivc tcst Iov thc Io!!owing itcm
# Economizei leadeis, coils, iping fiom economizei io sieam dium,
: Sieam dium
# uinace waiei walls, scieen, ioof wall, feedeis, iisei ,Waiei walls leadeis
Saiuiaiion sieam pipe
iimaiy, secondaiy supei leaiei
Conneciing pipe beiween piimaiy supeileaiei and secondaiy supeileaiei
Releaiei
Main S sieam pipes
nspeciion iiem
# Exieinal visual inspeciion
: nieinal visual inspeciion wiil endoscope
# T foi iliclness measuiemenis by T
MT and T on ciicumfeieniial welds
MT on piping aiiaclmenis
Meiallogiaplic inspeciion by plasiic ieplicas
MT on nozzles welds of ile coil iubes
MT on nozzles welds io ile slell of ile inlei]ouilei pipe
Le mlnlmum requlred Llckness
9= minimum required thickness.
= outside diameter of cylinder.
0= thickness factor for expanded tube ends.
!= maximum allowable working pressure.
$= maximum allowable stress value at the design temperature of the metal.
eslgn / CperaLlng lnformaLlon
for calculaLlon of remalnlng Llme based on Llckness
O Design infoimaiion
O maieiial iype oi giade
O Nominal ouiside diameiei
O Designing piessuie
O Design life
O Deign iempeiaiuie
O Oiiginal nominal iliclness
O Opeiaiing infoimaiion
O Maximum iube meial
iempeiaiuie
O Noimal opeiaiing piessuie
O Oiiginal measuied minimum
iliclness
O Meial ilinning iaie
Thickness
measurements
of water waII
tubes furnace
M|n|mum requ|red th|ckness for Sc
inimum required thickness for different working
conditions for materiaIs SA178- c
Samp|e tube
Dcstvuctivc tcst Iov thc Samp!c tubc ov Watcv Wa!! ,SR and RH tubcs
O ife diagnoses based on clecl of meial siiuciuie, iliclness, innei scale, eic
O Sample iube iales accoiding io ile iesuli of laidness measuiemeni
O Invcstigation Itcms
O Visual inspeciion
O Non desiiuciive iesi
O Clemical analysis
O Measuiemeni of ile iube dimension
O aidness measuiemeni
O Cioss seciional miciosiiuciuie obseivaiion
O Sieam oxidaiion obseivaiion
O Cieep iupiuie iesi
O Measuiemeni of ile innei scale iliclness
O InIovmation
O Maieiial of Sample iube
O iube dimension
sample Lubes
Thinning oI bu!gcd zonc Intcvna! suvIacc sca!c Extcvna! suvIacc
sca!c
Cpt|ca| m|crograph
5ticaI microgra5h of non-bIuged zones tube waII side showing
ferrite -5earIite structure with no
internaI defects
Norma| and deter|orated m|crostructure
normaI microstructure
( good condition tube)
Which shows a ty5icaI
ferritic 5earIitic
structure
deteriorated
microstructure which
shows the
decom5osition of the
5earIitic coIonies
Ilsual lnspecLlon for oLer parLs of boller
O Buinei
O Wind Box
O angei foi iisei pipe
O Ouiei casing
O Slin casing
O Buclsiay
JaLer CuallLy Survey
Tlis inspeciion io confiim ile cause of ile scale
geneiaiion
O Inspcction itcms
O Clecl of laboiaioiy analysis meilod foi qualiiy iiems
O Confiimaiion of waiei qualiiy iesulis ai pievious load opeiaiion
O Clecl of insiiumeni condiiion on sampling iacl used foi waiei
qualiiy coniiol
O Confiimaiion of value and iion]coppei balance in ile cycle
Ilsual lnspecLlon for aux LqulpmenL
Tlis inspeciion io confiim ile cause of ile scale geneiaiion
O Condensei loi well
O Condensei iube side
O Deaeiaioi
O -feed waiei leaiei
O eed waiei ianl
O -feed waiei leaiei
lg pressure parLs lnspecLlon deLalls
# Economizei leadeis ,coils, iping fiom economizei io sieam dium,
: Sieam dium
# uinace waiei walls, scieen, ioof wall, feedeis, iisei ,Waiei walls leadeis
Saiuiaiion sieam pipe
iimaiy, secondaiy supeileaiei
Conneciing pipe beiween piimaiy supei leaiei and secondaiy supeileaiei
Releaiei
Main S sieam pipes
Lconomlzer
O DE ov hcadcvs
O Exieinal visual inspeciion
O nieinal visual inspeciion wiil endoscope
O Measuiemeni of iliclness by T
O MT on nozzles welds of ile coil iubes and leadeis aiiaclmenis
O MT and T on ciicumfeieniial welds beiween leadei and conical pieces
O DE ov tubc
O Exieinal visual inspeciion
O Measuiemeni of economizei iube and langei iube iliclness wiil endoscope
O T foi iliclness measuiemenis
O DE ov Piping Ivom cconomizcv to stcam dvum
O Exieinal visual inspeciion foi piping, langeis and suppoiis
O T foi iliclness measuiemenis
O MT and T on ciicumfeieniial welds
O MT on piping aiiaclmenis
O MT on ile elbows exiiados
sLeam drum
O cIovc thc DT inspcctions, thc intcvna! pavts
oI thc dvum sha!! bc dismant!cd
O DE ov stcam dvum
O Exieinal visual inspeciion
O nieinal visual inspeciion
O T foi slell iliclness measuiemenis
O T foi lead iliclness measuiemenis
O MT and T on ciicumfeieniial and longiiudinal welds
O MT on sieam dium aiiaclmenis (saddles and accessoiies)
O MT on nozzles welds
O DE ov downcomcvs
O Exieinal visual inspeciion foi piping, langeis and suppoiis
O T foi iliclness measuiemenis
O MT and T on ciicumfeieniial welds
O MT on piping aiiaclmenis
furnace waLer walls screen roof wall
leeders and 8lser
O DE Iov Iuvnacc watcv wa!!s, scvccn, vooI wa!!
O Exieinal visual inspeciion
O T foi iliclness measuiemenis
O Meiallogiaplic examinaiion by plasiic ieplicas
O Samples foi desiiuciive iesi
O DE Iov Iccdcvs and viscv
O Exieinal visual inspeciion
O T foi iliclness measuiemenis
O DE Iov hcadcvs
O Exieinal visual inspeciion
O nieinal visual inspeciion wiil endoscope
O T foi iliclness measuiemenis
O MT on nozzles welds of ile coil iubes
O MT on biancles welds and leadeis aiiaclmenis, including diains iubes
SaLuraLlon sLeam plpe
O DE Iov cach pipc
O Exieinal visual inspeciion
O T foi iliclness measuiemenis
O MT and T on ciicumfeieniial welds
O MT on piping aiiaclmenis
O MT on ile elbows exiiados
rlmarySecondary SupereaLer
O DE Iov thc hcadcvs
O Exieinal visual inspeciion
O nieinal visual inspeciion wiil endoscope
O T foi iliclness measuiemenis
O T foi lead iliclness measuiemenis
O MT on nozzles welds of ile coil iubes
O MT on nozzles welds io ile slell of ile inlei]ouilei pipe
O MT and T on ciicumfeieniial welds beiween leadei and leads]
piping
O MT on leadeis aiiaclmenis
O Meiallogiaplic examinaiion by plasiic ieplicas
O DE Iov Coi!s
O Exieinal visual inspeciion
O T foi iliclness measuiemenis
O nieinal visual inspeciion wiil endoscope
O aidness measuiemenis
O Samples foi desiiuciive examinaiions
ConnecLlng plpe beLween prlmary and
Secondary SupereaLer esupereaLer A@S
O DE Iov connccting pipc
O Exieinal visual inspeciion
O T foi iliclness measuiemenis
O MT and T on ciicumfeieniial welds
O MT on piping aiiaclmenis
O MT on ile elbows exiiados
O Meiallogiaplic examinaiion by plasiic ieplicas
O DE Iov dcsupcvhcatcv ATPS
O Exieinal visual inspeciion
O nieinal visual inspeciion wiil endoscope
O T foi iliclness measuiemenis
O MT on ciicumfeieniial welds
O Meiallogiaplic examinaiion by plasiic ieplicas
8eeaLer
O DE ov cach onc oI thc hcadcvs
O Exieinal visual inspeciion
O nieinal visual inspeciion wiil endoscope
O T foi iliclness measuiemenis
O T foi lead iliclness measuiemenis
O MT on nozzles welds of ile coil iubes
O MT on nozzles welds io ile slell of ile inlei]ouilei pipe
O MT and T on ciicumfeieniial welds beiween leadei and leads]
piping
O MT on leadeis aiiaclmenis
O Meiallogiaplic examinaiion by plasiic ieplicas
O DE ov Coi!s
O Exieinal visual inspeciion
O T foi iliclness measuiemenis
O nieinal visual inspeciion wiil endoscope
O aidness measuiemenis
O Samples foi desiiuciive examinaiions
Maln SP sLeam plpes
O DE Iov cach pipc
O Exieinal visual inspeciion
O T foi iliclness measuiemenis
O MT and T on ciicumfeieniial welds
O MT on piping aiiaclmenis
O MT on ile elbows exiiados
O MT on nozzles welds io ile pipe
O Meiallogiaplic examinaiion by plasiic ieplicas