On-site Inspection and Remaining Life Assessment for Boiler Pressure Parts *Using our ‘Smart Sleeve’ commercially on a power plant for the first time*


The client contacted ETD to submit a proposal on Remaining Life Assessment (RLA) for boiler pressure parts by performing on-site inspection, analysis and assessment on tubes, T-piece nozzles, stub tube weldments and hot reheat pipe weldment for final superheater (FSOH) & reheater (ROH). The work involved performing on-site inspections - ultrasonic thickness measurements (UT) of tubes (wall thickness & bore oxide scale), EMAT (Electromagnetic Acoustic Transducer), replication and hardness measurements of selected locations. The inspection data was then used to estimate effective tube metal temperature and identify material degradation which could be used for damage assessment and predicting the remaining life of outlet headers and tubes of the FSOH & ROH.

The objectives and scope of the work to be carried out were:

  • Reviewing the drawings of FSOH & ROH, tube banks of the boiler to be studied and identify accessible test locations for on-site inspections;

  • Performing on-site ultrasonic thickness (UT) measurements of tube wall thickness and bore oxide scale for FSOH & for ROH tubes;

  • Performing on-site EMAT (Electromagnetic Acoustic Transducer) testing of tube wall thickness for FSOH & ROH tubes;

  • Performing on-site replication and hardness measurements on straight tubes, T-piece nozzle weldments, stub tube weldments and hot reheat pipe weldment for FSOH & ROH for the first time, using our newly developed ‘Smart Sleeve’ Hardness Tester commercially on a power plant;

  • Assessing all replicas by using OM (optical microscope) to confirm the damage condition. Further assessment was also made of selected P/T/F91 & T23 replica(s) by using SEM (Scanning Electron Microscope), if necessary, to confirm the damage condition;

  • Assessing the damage and material degradation of FSOH & ROH outlet headers, tubes, T-piece nozzle weldments, stub tube weldments and hot reheat pipe weldments based on the replication and hardness measurements data;

  • Reviewing & analysing UT inspection data and estimation of wall thickness loss & tube metal temperature;

  • Assessing the remaining life of FSOH & ROH components based on estimated tube metal temperature and other inspection data;

  • Reviewing & analysing previous failures, inspection and maintenance data for other pressure parts (i.e. economiser, etc) of the boiler to complete the life assessment study;

  • Preparing a full report including results of on-site inspections, analysis results of damage & life assessment study and make recommendations for any further actions to be taken for safe and reliable operation of the boiler.

For more information about of Remaining Life Assessment & Extension services please click here.

Offer of Unique P91, P92 Services for New & Running Plants

In this P91/P92 Services Brochure you will find useful and interesting information on ETD’s unique P91, P92 Services for New & Running Plants. These include:

a) Inspection, Monitoring, Assessment & Life Extension Services: Over the last decade through its collaborative research programmes, with its international industry partners, involving large pipe testing ETD has developed a suite of specialist inspection and monitoring techniques and life assessment methodologies that it offers to plants worldwide. These are offered in addition to the conventional NDE techniques for the detection and sizing of defects, together with replication and portable hardness testing for component condition and remaining life assessment. ETD carries out code-based calculations of creep life using either deterministic or probabilistic (another of ETD specialities) methodologies. Examples of these techniques include: Scanning Force Microscope (SFM) for early stage damage detection, Miniature sample removal (boat sampling) for quality checks and life/condition assessment, Precision Portable Hardness Tester (known as ‘Smart sleeve’), ‘Obikou’ for Pipe Strengthening and Life Extension and Defect/Crack Assessment.

 b) Root Cause Failure Analysis: Over the years ETD has developed an expertise in the root cause failure investigation of P91 and P92 components/welds. In the recent past, ETD has investigated a range of failures of T91 tube components and welds, and cracking in P91 pipes and drain-line components in conventional boilers and HRSGs. In these investigations, ETD identifies the root cause of the damage, and proposes remedial actions and solutions to the problem.

c) Consultancy & Guidelines on Materials & Welding: ETD provides P91 and P92 users with advice and guidance on the metallurgy, welding and heat treatment of these steels. This service includes reviewing weld procedure specifications (WPS) for similar and dissimilar metal welds, inspection of NDE records, and guidelines for repair welding of P91. The advice is provided to both the plant operators and designers/ manufacturers. This advice is based on ETD’s P91 experience in a number of Group Sponsored Projects including its running of the International P91 Users Group (Int. P91UG) for international industry over more than a decade and its involvement as consultants to many a power plants worldwide.

For further details of our P91/P92 services and opportunities being offered, please click on the image above.

Renting of Electrical Discharge Sampling Equipment to a client for a project in the Middle East


ETD was approached by a European based company to rent their Electrical Discharge Sampling Equipment (EDSE) for a month to cut samples from a power plant in the Middle East.

The EDSE was developed by ETD in collaboration with international partners to aid in the condition and life assessment of components. The sampling of in-service components has long been seen as an effective way of determining actual material properties and sub-surface material condition. However, many of the existing methods of sample removal require mechanical cutting which can deform the surface and usually require weld repair. Unlike the traditional mechanical ‘boat sampler’, with EDSE, the surface damage if any is of the level of only a few microns. EDSE can also be used to cut out specimens for small punch testing and miniature creep, fatigue or tensile testing for more accurate quantitative life assessment.

The EDSE is available to rent or for purchase. For more information on our EDSE services, please click here.