Establishment of Non-destructive Testing and Condition Monitoring Facility for

Boiler Inspection, Maintenance and Safety Operation

Slide 1
I am ….. Thanks for giving me the opportunity to present this workshop.
I am going to discuss on Establishment of Non-destructive Testing and Condition Monitoring Facility for
Boiler Inspection, Maintenance and Safety Operation

Slide2
• We all know, Safety is a top concern for all industry.
• Regular Inspection and maintenance helps to prevent accidents by detecting and correcting
potential problems before they can lead to accidents.
• We, SAJ Engineering, provide Non Destructive Testing and Condition Monitoring Instruments for
our local boiler manufacturer and industrial user for quality assurance

Slide 3
I am going to discuss in short about the instruments which we provide to perform these analysis for
quality assurance of Boiler. Such as –
01. Material Composition Analysis 13. IR Thermal Inspection
02. Ultrasonic Thickness Gauging 14. Coating Thickness Gauge
03. Visual Inspection 15. Dew point meter
04. Radiography Testing 16. Sound Level Measurement Meter
05. Phased Array Ultrasonic Flaw Detection 17. Telescopic Gage Set
06. Dye Penetrant Test 18. PWHT
07. Magnetic Particle Testing 19. Pulsed Eddy Current Reinvented
08. Hydraulic Pressure Test /Corrosion assessment Under Insulation
09. Hardness Testing 20. Acoustic Plus Reflectometry Inspection
10. Remote Visual Inspection System
11. Safety valve inspection and calibration 21. Vibration Analysis for Mechanical
12. Ultrasound and Valve Inspection 22. Vibration Analysis for Civil Structure
23. Rebound Hammer for concrete test

Slide 4
At First it is required to check the materials which have used to manufacture the Boiler tubes. If it’s
steel, then which kind of steel has used? To confirm material purity, composition, grade XRF/PMI is the
best method for such type of confirmation.

Slide5
Then Thickness determination is another important parameter of the inspection.
On this regard, Ultrasonic thickness gauge is used to determine thickness of boiler pipes, viewing cross
sectional image of checking point.
 Establishment of Non-destructive Testing and Condition Monitoring Facility for
Boiler Inspection, Maintenance and Safety Operation

Slide 6
Then Flaw detection. Flaw detection is the most essential part of the boiler inspection.
• Ultrasonic Flaw Testing is very effective to find welding internal defects like –
– Cluster porosity
– Void
– Incomplete penetration
– Slag inclusion etc.
• Phased Array Ultrasonic test method is very helpful for checking and confirming internal defect
size, depth and measurement.

Slide 7
Then it is also very important to examine the boiler visually by outside.
We also provide the tools and accessories for this visual inspection of the boiler, which are required to
check the welding procedure and weld preparation, like-
– Root gap
– Root face
– Bevel angle
– Welding defect
– Porosity
– Under cut
– Incomplete penetration
– Slag inclusion etc.
Welding dimension, Size, length and location of all welds whether these conform to the drawings /
specifications / Code or not?

Slide 8
There are also some parts of Boiler where we cannot reach by naked eyes. Regarding this we provide
instruments to look into those remote areas without opening or disassemble or destroy. This is helpful
to inspect and examine the visual flaws of those areas. Such as –
– Cracks
– Corrosion
– Contamination
– Structural integrity and other discontinuities.

Slide 9
Then Radiography Testing
Radiography is applicable for finding internal defect of welding and convenient for boiler shell joint
inspection.

Slide 10
Dye Penetrant Test
Dye penetrant testing is applicable for find surface crack/defect for welding joint or material. A dye
applied on the surface to aid the visual inspection.
 Establishment of Non-destructive Testing and Condition Monitoring Facility for
Boiler Inspection, Maintenance and Safety Operation

Slide 11
Magnetic particle testing: Magnetic particle testing method is suitable for finding surface and sub
surface welding defect like-
– Incomplete Fusion
– Slag Inclusion and Porosity
– Inadequate Joint Penetration
– Under Cut, Seams, Laps
– Grinding cracks
– Quenching cracks
– In-service damage
– Fatigue

Slide 12
Then Hydraulic Pressure test
This test involves filling the vessel or pipes of the boiler with a liquid, usually water, which may be dyed
to aid in visual inspection. By this boiler can be tested for strength and leaks. Testing of pressure vessels
is very important because such containers can explode if they fail under pressure.

Slide 13
Then we also provide the instrument for hardness testing
Hardness Testing is a widely used method for determining hardness of materials

Slide 14
We provide instruments for IR thermal Testing to determine
– Hot spot
– Cold spot
– Slack/loose connectors
– Overheated motor bearing
– Damaged or missing insulation
Slide 15
We provide Acoustic Pulse Reflectometry (APR) Inspection System dedicated for boiler tube corrosion
assessment.

It is based on the measurement of one-dimensional acoustic waves propagating in tubes. Any change in

the cross sectional area in the tubular system creates a reflection, which is then recorded and analyzed
in order to detect defects.
 Establishment of Non-destructive Testing and Condition Monitoring Facility for
Boiler Inspection, Maintenance and Safety Operation

Slide 16
Corrosion under insulation is the biggest challenge for servicing the boiler.
We provide Pulsed Eddy Current Reinvented for assessment corrosion under insulation to overcome this
barrier.

Slide 17

• Vibration is the first indication of a machine’s health.

• Vibration can alert us for many different conditions that may indicate potential machine failures

Slide 18

We also provide Coating Thickness Gauge & Dew Point meter which are Applicable for measuring the
thickness of paint coating and understanding the Condition of Environment where boilers are operated.

Slide 19

We provide Sound Level Measurement Meter, which helps to measure the sound level generating
during boiler operation.

Slide 20
We provide Rebound Hammer for concrete test to check the Strength of Concrete Structure

Slide 21

We provide Exhaust Gas Analyzer to ensure safe operating conditions, determine combustion efficiency
and perform emissions testing.

This instrument directly measures and displays O2, CO, flue-gas temperature, draft, differential pressure,
and combustion air temperature and optionally measures and displays NO, NO2, SO2.

Slide 22

At last we can say the ultimate goal of these inspections is to minimize loss of life and property, through
the accepted construction and fabrication, as well as the safe operation and maintenance of boilers and
pressure equipment.