Boiler Life Assessment

PRESENTED BY
L. V. Rama Rao

Apt Inspection Technologies

Plot No. 137, 1st Floor,Telecom nagar, Gachibowli,

Hyderabad-500032.T.S
 Contents

1. Apt profile
2. List of employees
3. List of Major Clients with Job
4. List of Equipment
1.Apt profile
Apt inspection technologies (AIT) is an ISO 9001:2008 certified organization.
AIT is promoted by highly experienced and qualified personnel from power sector
having 25 years of vast experience in Q A, in-service inspection (ISI),failure
investigation.
AIT has entered MOU with Life Prediction Technologies Inc,Canada for life extension
studies of HIGH and Xact Tube for assessing boiler tube life.
Apt inspection technologies services:
1. Condition Assessment of the Components
2. Condition Assessment of Boiler Components
3. Structural integrity Management & Engineering Services
4. NDT Inspection Services
5. Technical Consultancy Services
6. Training & Certification programs
 Employee Designation Experience
L.V . Rama Rao Managing Director 25+years

Mr. Radha Krishna Technical Advisor 30years

Mr. Venkataramana Financial Advisor 20years

Mr. R.Bhanu Prasad Business Development 5years

officer/Senior NDT
Technical/Metallurgist
Mr. A.Venkateswarlu Vibration /condition 8years
monitoring Engineering

Mr.Narsing Rao Welding Expert 35+years

Mr.Rama Rao ISO Audit Advisor 20years

Miss. Lakshmi Accounts & Admin Head 2years

Employee Designation Experience
Mr.Anil Kumar NDT Technician 4years

Mr.Subhas shaw NDT Technician 4years

Mr.Naresh Reddy NDT Technician 1+year

Mr. Ramakrishna Metallurgist 1+year

Mr. Kasiah Metallurgist 1+year

Miss.V.Sindhuja Metallurgist 4 years

Mr.K.Vamshi Krishna NDT Technician 1+year

Mr.D.Manohar Reddy NDT Technician 1+year

Employee Designation Experience

Mr.G.V.Vijay Sudheer NDT Technician 1+year

Mr. Santhosh NDT Technician 1+year

Mr. Murali NDT Technician 1+year

Mr. Harish NDT Technician 1+year

 3.List of Major Clients with Job

Association with CPRI JOB

CPRI Nagpur –UNIT-I,NTPC-Rihand
CPRI Nagpur –UNIT-II,NTPC-Rihand
CPRI Bengaluru-UNIT-III,NTPC-Rihand
CPRI Bengaluru-UNIT-IV,NTPC-Rihand
RLA , NDT
RLA,NDT
Oxide scale measurement, Hardness
Measurement, Insitu-Metallography,
Thickness survey
Oxide scale measurement, Hardness
Measurement, Insitu-Metallography,
Thickness survey
 Our own projects JOB

Ganapati sugars, Ranga reddy UTG Thickness,RT for Economizer tubes.

Gayatri sugars, Kama reddy Thickness and UT

Semb corp Gayatri, Nellore Boiler tube failure Analysis

Meenakshi Energy, Nellore Ultrasonic thickness survey, PMI of

power cycle pipelines

NTPC Ramagundam Film reviewing

NCC Nellore NDT

AP Genco, Nellore PMI,UT

Simhapuri, Nellore Boiler thickness, Thickness survey &

Boiler inspection.

BHEL,T.S Genco, Warangal UT, MPI, Hardness on headers

 4.List of Equipment

S. No. Equipment Quantity Application

1 Ultrasonic flaw detection

Equipment
With accessories
A) Starmanns Dio 1000 UFD, 1 To detect the internal
B) Modsonic-Einstein II TFT 3 discontinuities upto 500mm
UFD depth.
C) Digiscan DS 322 UFDU 1
D) Ultrasonic Thickness Gauging 6
S. No. Equipment Quantity Application
2 Magnetic particle
equipment
With accessories
A) SquareMag 2 To detect the
MPI yoke surface and sub-
B)Radent MPI 3 surface
Yoke discontinuities
C)EECI MPI Yoke 1
D)Permanent 1
Magnet
E)Radent MPI 2
Cable Wrap/ Prod
1500Amps
F)Radent MPI 1
cable wrap 6000
Amps
G)K-Electronics 1
MPI cable wrap
6000 Amps
H)UV Black Light 4
I)Gauss meter 3
S. No. Equipment
3 Penetrant test Equipment
A)Penetrant
B)Developer
C)Cleaner
D)Flourocent penetrant
4 Portable Hardness Tester
Yamayo TH-370 with calibration
block
5 Metallography Equipment
A) Inverted Metallurgical
Microscope Radical RMM-2
B) Dual Disc Polishing Machine
C) Portable Metallurgical
Microscope RMM-5
D) Metal Power Portable Polisher
E)Portable Hand polisher-BOCH
6 Olympus-38dL plus UT
Quantity Application
Used for surface flaws
detection open to the Air
1 Used for to check the
hardness of the material
1
Metallurgical degradation –
1 creep, failure investigation
1 etc…
1
2
1 Steam side oxide scale
thickness measurement
S. No. Equipment Quantity Application

7 RT Equipment With accessories 1 set To find out the internal

A) Radiography film viewer (LED base) (out defects of the weld
B) Iridium 192 source sourcing)
8 Condition Monitoring of Rotating 1 To predict the rotating
Equipment's (NFT & Vibration Analysis) equipment's failure
COCO -80

9 Universal Testing Machine Out tensile and bend test.

sourcing
12 Niton Xl(PMI) Out To find out the chemical
sourcing composition
13 Boroscope Out Visual examination of
sourcing inaccessible areas
 8.Life Evaluation by Inspection
FAILURE DAMAG CAUSA PHENOMENON LIFE EVALUATION INSPECTION ITEM

 CREEP Clogging with Swelling Outside diameter and Metallurgical inspection for SH, RH
foreign material Metal structure thickness measurement header,
Deposition and change Metallurgical inspection Metallurgical inspection and NDT (UT)
growth of scale on for main steam pipe line and high
Inner surface temperature RH pipe
Long-term stress

FATIGUE Cycle thermal Growth of crack Stress analysis NDE (PT, MT) of spacer welded for SH
stress Surface crack inspection and RH Tube
(PT,MT)

CORROSION Cyclic thermal Interaction of Ultrasonic test Sample tube inspection for SH, RH and
FATIGUE stress under corrosion and Sample tube inspection water wall
corrosive fatigue Check of Burner Nozzle and Wind Box
environment Damper

CORROSION High temp Thickness Annual thickness  measurement of tube thickness for SH
EROSION corrosion thinning measurement ,RH, Water Wall and Eco by UT
Low temp Steam drum
corrosion Boiler aux
Ash erosion Eco Hanger tube by endoscope, etc
 Sample tubes

Thinning of bulged zone Internal surface scale External surface scale

Optical micrograph

Optical micrograph of non-bluged zones tube wall side showing ferrite –

pearlite structure with no
internal defects
Normal and deteriorated microstructure

normal microstructure deteriorated

( good condition tube) microstructure which
Which shows a typical shows the
ferritic pearlitic structure decomposition of the
pearlitic colonies