Sample Gtrack

Gtrack v 3.
Inspection Report Created on 7/26/2006 9:34 a7/p7

Page 1
Station: UDC Unit: 2 Report Name: 39-Reheat Front Pendant
AREA: Reheat Front Pendant

By: UDC Inspection Team
The area was numbered from boiler left (west) side to

boiler right (east) side. Tubes were counted from front
(south) to rear (north) or top to bottom unless otherwise
specified.
Items were marked with white grease stick.
=====================================================================================
P R I O R I T Y # A R E P A I R S
=====================================================================================
Repair item #: 1
Area: Reheat
Repair #: 1-a Record:# 372

Action: TUBE REPLACEMENT
Priority #: A
General location is Reheat, Front Pendants,

IR-7.
Specific location: Tube #:12 Element #:141
Elevation: 1457'
Length: 5'
Cause: Erosion (soot blower)

Appearance: Polished
Material: 2.25" OD x .148" MWT x SA-213TP304H
The UT Result is .094
Due to wall loss from erosion, replace tube 12 (trailing tube) of

assembly 141. From the centerline of the bend, the lower cut line will
be 21” upward extending for a total length of 6’ 2”.
This tube replacement will not include the lower radius bend.
Work Order: _____________
Status: Work Completed – Assy 141 Replaced

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 1995-2003 UDC 502 957 7525

Gtrack v 3.5

Page 2
Repair #: 1-b Record:# 371

Priority #: A

IR-7.
Elevation: 1457'
Length: 7'

The UT Result is 0.069”
Due to wall loss from erosion, replace tube 12 (trailing tube) of

assembly 2. Measured from the centerline of the radius bend, the lower
cut line on the horizontal section is 18” and the upper cut line is 7’.
The UT result @ the radius bend was 0.107”.
Work Order: _____________
Status: Work Completed – Assy 12 Replaced

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Repair #: 1-c Record:# 375

Priority #: A
General location is Waterwall North, Hanger

Tubes, IR-7.
Specific location: Tube #:106 through 107
Elevation: 1457'

Appearance: Eroded Tubing
.320" MWT
Tube 107 has 48% wall loss and tube 106 has 25% wall loss. Tube 106
also has an old attachment that has an erosion gouge under it from
blower channeling. These tubes are to be replaced just below this area
with the replacement of the upper slope. Add at least 4’ of tube
material to these 2 tubes when they are replaced below.
Work Order: _____________
Status: Work Completed – Assy 106 and 107 Replaced

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 1995-2003 UDC 502 957 7525
Gtrack v 3.5

Page 3
Repair item #: 2
Area: Extended Side Wall

Action: PAD WELD
Priority #: A
General location is Extended Side Wall, West

Side, Top.
Elevation: 1485'
Length: .3'
Cause: Erosion (fly ash)

Appearance: Eroded
Apply a 3" x 2" pad weld to the side wall located adjacent to the water
cooled spacer tube as it descends from the roof penetration. Repair is
located approximately 2' down from the roof line.
Use vertical stringers and feather edges. Do not horizontal weave pad
weld. Down hand is suggested to keep the temperature as cool as
practical. Do not pad weld if copper deposition is present on the
internal surface of the tubing. Use TIG if the tube remaining wall is
less than .125".
Work Order: _____________
Status: Work Completed – Sidewall tube pad weld repaired

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Action: PAD WELD
Priority #: A
General location is Waterwall

North, Hanger Tubes, IR-6.
Specific location: Tube #:1
Elevation: 1475'
Length: 1.5'

.320" MWT
Apply a 17” pad weld on the trailing side of hanger tube 1 centered in IR-6 blower
path.
Work Order: _____________
Status: Work Completed – Tube 1 was pad weld repaired

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 1995-2003 UDC 502 957 7525
Gtrack v 3.5

Page 4
=====================================================================================
P R I O R I T Y # B R E P A I R S
=====================================================================================
Repair item #: 3
Area: Reheat

Action: SHIELD INSTALLATION REPAIR
Priority #: B

IR-6.
Specific location: Tube #:11 Elements #:1
through 142
Elevation: 1475'
Length: 4'

The UT Result is below 85% MWT
Blower path 6 has eroded tube 11 (the trailing tube) throughout the
front pendants. UT readings were taken randomly and the results showed
consistent wear averaging .117 inches. It is recommended to shield the
path with a 4 foot minimum length shield that fits tight to the tubing.
Clean tubing well before installation to ensure the maximum life of the
shield. Follow the blower path allowing for sag towards the middle of
the furnace.
Repair by installing shield(s). Do not tack to tube in more than one

location. Orient shield in the direction of possible erosion. Slant
shields to match droop of soot blower lance. Weld with 7018 or inconel.
Work Order: _____________ Status: Inspected

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 1995-2003 UDC 502 957 7525

Gtrack v 3.5

Page 5

Priority #: B
General location is Waterwall North, Hanger

Tubes, IR-6.
Elevation: 1475'
Length: 4'

.320" MWT
Shield tube for a minimum of 4 feet centered on the erosion area.

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 1995-2003 UDC 502 957 7525

Gtrack v 3.5

Page 6

Priority #: B
General location is Reheat, Middle Crossover

Section.
Cause: Abrasion Damage or Mechanical Rub

Appearance: Abraded
Install a 6" section of shielding encompassing the abraded area on the

following middle horizontal crossover assemblies/tube #:
12/1(UT-.126)
21/2
24/1
27/2
31/2
48/1
In addition, install an 10" section of shielding on the rear wall hanger tubes
adjacent to the noted reheat tubes. All abraded areas were visually identified and
were estimated to be below 85% of MWT. The middle horizontal crossover tubes were
counted top to bottom.

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 1995-2003 UDC 502 957 7525

Gtrack v 3.5

Page 7
Repair #: 3-d Record:# 382

Priority #: B
General location is Reheat, Upper Crossover

Section.

Appearance: Abraded
Install a 6" section of shielding encompassing the abraded area on the

following upper horizontal crossover assemblies/tube #: 14/1 and 18/1.
In addition, install a 15" section of shielding on the rear wall hanger
tubes adjacent to the noted reheat tubes. All abraded areas were
visually identified and were estimated to be below 85% of MWT. The
upper horizontal crossover tubes were counted bottom to top. Once the
area is spread open for repair, inspect the condition of tubes 2 and 3
and apply repair criteria.

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 1995-2003 UDC 502 957 7525

Gtrack v 3.5

Page 8
Repair #: 3-e Record:# 384

Priority #: B

Section.

Appearance: Abraded
Install an 8" shield encompassing the side of the radius bend on

horizontal crossover tube 1 of assembly 15 at the point of intersection
with assembly 14. In addition, install a 6" section of straight shield
on tube 2 of assembly 14. All abraded areas were visually identified
and were estimated to be below 85% of MWT. (Assembly 14 tubes were
counted north to south; middle crossover tubes were counted top to
bottom.)

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 1995-2003 UDC 502 957 7525

Gtrack v 3.5

Page 9
Repair #: 3-f Record:# 410

Priority #: B

IR-7.
through 129
Elevation: 1457'
Length: 4'

The UT Result is .122 & .118
Shield tube 12 (trailing side tube) of assembly 128 on the north side
face centered on blower path 7R.

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 1995-2003 UDC 502 957 7525

Gtrack v 3.5

Page 10
Repair #: 3-g Record:# 476

Priority #: B

IR-7.
through 77
Elevation: 1457'
Length: 4'

The UT Result is .108 & .122
Shield tube 12 (trailing side tube) of assemblies 76 and 77 on the

north side face centered on blower path 7R. Assembly 76 tube has just
exceeded the 75% MWT.

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 1995-2003 UDC 502 957 7525

Gtrack v 3.5

Page 11
Repair #: 3-h Record:# 477

Priority #: B

IR-7.
Elevation: 1457'
Length: 4'


face centered on blower path 7R.

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 1995-2003 UDC 502 957 7525

Gtrack v 3.5

Page 12
Repair #: 3-i Record:# 478

Priority #: B

IR-7.
Elevation: 1457'
Length: 4'


face centered on blower path 7L.

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 1995-2003 UDC 502 957 7525

Gtrack v 3.5

Page 13
Repair #: 3-j Record:# 475

Priority #: B

IR-7.
Elevation: 1457'
Length: 4'

Shield tube 12 (trailing tube) of assembly 80 on the north side face

centered on blower path 7R.

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 1995-2003 UDC 502 957 7525

Gtrack v 3.5

Page 14
Repair item #: 4
Area: Roof Tubes

Action: ALIGN AND RE-ATTACH
Priority #: B
General location is Roof Tubes, West Side.

Elevation: 1487'
Length: 12'
Appearance: Bowed Tubing
Pull first roof tube back up into position, attach support clips to
collector bars, and restore refractory layer above. The tube is bowed
down at the crossover section for a run of approximately 10 - 15 feet.

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 1995-2003 UDC 502 957 7525

Gtrack v 3.5

Page 15
Repair item #: 5
Area: Reheat

Action: FLEX TIE REPLACEMENT
Priority #: B

Elevation: 1455'
Cause: Fatigue (thermal)

Appearance: Broken
Replace flex tie between tube 1 & 2 located approximately 5' up from
the bottom loop of the pendant. It is recommended to clean the front
of pendant and grant access to thoroughly inspect for cracked or
missing flex ties, etc.
Try to install the new clips in other locations from the original heat
affected zone. Weld with tube 7018 or inconel.

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 1995-2003 UDC 502 957 7525

Gtrack v 3.5

Page 16
Repair item #: 6
Area: Reheat

Action: ROD-OUT ACCUMULATION (P2)
Priority #: B
General location is Reheat, @ Reheat Middle

Crossover Section.
Elevation: 1484'
Appearance: Blocked Gas Lane
It appears that the ash accumulation at the top section of the

front/rear reheat pendant is plugged approximately 60% from left to
right side. The pluggage extends down approximately 6' from the roof
line. Ash accumulation and slagging characteristics such as this
indicate a high fouling rate, low fusion point consistency throughout
component. These characteristics are more prevalent with a low BTU
burning fuel, such as Powder River Basin. To reduce high fouling, and
to increase ash fusion temperatures, it is recommended to consider the
following options: Blend coal with a bituminous to increase BTU, and/or
de-slag the waterwalls. Removing the slag build up from the waterwalls
will increase heat transfer in the fire box, therefore, reducing
fouling points in the pendant paths etc. Less pluggage and slag build
up would be evident throughout the pendants.

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 1995-2003 UDC 502 957 7525

Gtrack v 3.5

Page 17
=====================================================================================
P R I O R I T Y # C R E P A I R S
=====================================================================================
Repair item #: 7
Area: Roof Tubes

Action: PEG FIN REPLACEMENT
Priority #: C
General location is Roof Tubes, @ front reheat

pendant.
Specific location: Element #:7
Elevation: 1487'
Cause: Fatigue (thermal)

Appearance: Burnt or Distorted
It appears that the peg fin located between the front pendant tubes at
the roof tube intersection is fatigued and burnt away. This fatigue has
allowed the refractory to degrade and for temperatures to increase at
the penthouse seal box locations. It is evident that slag accumulations
are blocking access to inspect several additional elements at the roof
penetration. It is recommended to remove ash build up at this location
to inspect for all fatigued areas.
Remove existing peg fin remnants and replace with new. Install fins
with non-continuous side against tube and apply short welds not
extending past each fin break.

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 1995-2003 UDC 502 957 7525

Gtrack v 3.5

Page 18
Repair item #: 8
Area: Reheat

Action: REMOVE ASH AND DEBRIS
Priority #: C
General location is Reheat, @ top crossover.

Elevation: 1483'
Appearance: Ash build up
The top section of the reheat crossovers could

not be inspected due to excessive ash build
up. UDC recommends that this debris be removed
for a 100% visual inspection.
Work Order: _____________ Status: Not Inspected

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 1995-2003 UDC 502 957 7525

Gtrack v 3.5

Page 19
Repair item #: 9
Area: Reheat

Action: MONITOR CLOSELY
Priority #: C
General location is Reheat, Spacer Tube, Top.

Elevation: 1485'

Appearance: Eroded
Material: 2.0" OD x .240" MWT x SA-210A1
Monitor erosive wear located on the bottom edge of the WCS tubes as
they bend at the West wall. Damage is located approximately 2' down
from the roof line. Lowest UT result found was on the bottom tube
resulting in .204".
Monitor this item during future overhauls.

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Priority #: C
General location is Extended Side Wall, @

Reheat Middle Crossover Section.
Appearance: Eroded
Located within the reheat middle crossover section, erosion is

occurring on both the WCS tube and the west sidewall tube at the point
of intersection. Monitor this item during future overhauls; repair
criteria does not apply at this time.

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 1995-2003 UDC 502 957 7525
Gtrack v 3.5

Page 20

Priority #: C
General location is Roof Tubes, @ Reheat

Middle Crossover Section.
Elevation: 1485'

Appearance: Eroded
Monitor erosion on the bottom edge of roof tubing at the crossover

intersection as well as to the front of the front reheat pendant.

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Repair #: 9-d Record:# 397

Priority #: C
General location is Reheat, @ Reheat Middle

Crossover Section.
Elevation: 1482'

Appearance: Abraded
It appears that the intersection of the North waterwall hanger tubes

and the middle reheat crossover tubes are abrading. Monitor this
intersection during every scheduled shut down, and make repairs as
inspection results indicate.

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 1995-2003 UDC 502 957 7525
Gtrack v 3.5

Page 21
Repair #: 9-e Record:# 421

Priority #: C

Front.
Elevation: 1449'

It appears that the inner radius bends of the front/bottom loops are
showing signs of erosive polishing. UT results indicate that tubes are
still well above design MWT. No repairs are necessary at this time,
monitor during future shut downs.

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 1995-2003 UDC 502 957 7525

Gtrack v 3.5

Page 22
Repair #: 9-f Record:# 423

Priority #: C
General location is Waterwall Division, @ Arch

nose, West side.
Elevation: 1448'

Monitor erosive wear located at the arch nose intersection. Erosion

pattern appears to exist on the tubes just to the front of the arch, v

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 1995-2003 UDC 502 957 7525

Gtrack v 3.5

Page 23
Repair #: 9-g Record:# 389

Priority #: C
General location is Roof Tubes.

Elevation: 1487'

Appearance: Eroded
Monitor erosive wear located on the roof tubes from the SH platens back
to the reheat front pendants. It is recommended that these locations be
inspected thoroughly once scaffolding/access is granted. It appears
that the roof tubes adjacent to the platens and pendants are showing
more wear.

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v
Repair item #: 10
Area: Reheat

Action: INFORMATION ONLY
Priority #: C

Section.
Appearance: Ash Accumulation
Due to the amount of fused ash on the Upper Horizontal Crossover

section, a thorough inspection for abrasion damage could not be
conducted. It is recommended that the area be cleaned thoroughly and
re-inspected during the next planned overhaul.

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 1995-2003 UDC 502 957 7525
Gtrack v 3.5

Page 24

Action: INFORMATION ONLY
Priority #: C

IR-7.
Elevation: 1453'
Appearance: Out of alignment
On assemblies 64 and 136, the lower loop is out of alignment by 3/4

tube diameter.

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 1995-2003 UDC 502 957 7525

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Gtrack v 3.

Inspection Report Created on 7/26/2006 9:34 a7/p7

AREA: Reheat Front Pendant

The area was numbered from boiler left (west) side to

Items were marked with white grease stick.

Repair #: 1-a Record:# 372

General location is Reheat, Front Pendants,

Cause: Erosion (soot blower)

Material: 2.25" OD x .148" MWT x SA-213TP304H

The UT Result is .094

Due to wall loss from erosion, replace tube 12 (trailing tube) of

Work Order: _____________

Status: Work Completed – Assy 141 Replaced

 1995-2003 UDC 502 957 7525

Inspection Report Created on 7/26/2006 9:34 a7/p7

Repair #: 1-b Record:# 371

General location is Reheat, Front Pendants,

Cause: Erosion (soot blower)

Material: 2.25" OD x .148" MWT x SA-213TP304H

The UT Result is 0.069”

Due to wall loss from erosion, replace tube 12 (trailing tube) of

The UT result @ the radius bend was 0.107”.

Work Order: _____________

Status: Work Completed – Assy 12 Replaced

Repair #: 1-c Record:# 375

General location is Waterwall North, Hanger

Cause: Erosion (soot blower)

Work Order: _____________

Status: Work Completed – Assy 106 and 107 Replaced

Inspection Report Created on 7/26/2006 9:34 a7/p7

Repair #: 2-a Record:# 381

General location is Extended Side Wall, West

Cause: Erosion (fly ash)

Work Order: _____________

Status: Work Completed – Sidewall tube pad weld repaired

Repair #: 2-b Record:# 406

General location is Waterwall

Cause: Erosion (soot blower)

The UT Result is .230

Work Order: _____________

Status: Work Completed – Tube 1 was pad weld repaired

Inspection Report Created on 7/26/2006 9:34 a7/p7

Repair #: 3-a Record:# 370

General location is Reheat, Front Pendants,

Cause: Erosion (soot blower)

Material: 2.25" OD x .148" MWT x SA-213TP304H

The UT Result is below 85% MWT

Repair by installing shield(s). Do not tack to tube in more than one

Work Order: _____________ Status: Inspected

 1995-2003 UDC 502 957 7525

Inspection Report Created on 7/26/2006 9:34 a7/p7

Repair #: 3-b Record:# 377

General location is Waterwall North, Hanger

Cause: Erosion (soot blower)

The UT Result is .266

Shield tube for a minimum of 4 feet centered on the erosion area.

Work Order: _____________ Status: Inspected

 1995-2003 UDC 502 957 7525

Inspection Report Created on 7/26/2006 9:34 a7/p7

Repair #: 3-c Record:# 378

General location is Reheat, Middle Crossover

Cause: Abrasion Damage or Mechanical Rub

Material: 2.25" OD x .148" MWT x SA-213TP304H