Experience Counts
Boiler Conditon Assessment
EXPERI ENCE COUNTS
Foster Wheeler has Engineered and Designed 25.5 GWe
of steam generation equipment over the past 100 years
WHY CONDI TI ON ASSESSMENT?
Units are being cycled daily due to legislation amd environmental regulations
High cost of accelerated damage due to cycle fatigue
Decreased maintenance budgets and reduced outage schedules
Average age of steam generating assets is over 30 years
Foster Wheeler has the experience and resources to implement
comprehensive Boiler Condition Assessment Programs
Each steam
generator is
inherently different
and requires
a customized
approach to
determine those
methods that will be
most cost-effective.
Double Reheat PC Boiler
HRSG CFB Package Boiler
Waterwalls
Downcomers
Steam Drums
SH, RH, ECONTubes
Headers
Critical Piping
Boiler Structure and
Supports
Flues and Ducts
Burners
A plan is prepared after a thorough
review of the plants operations
(both current and historical). As
time permits, both a hot and cold
walkdown should be performed.
Level I Condition Assessment
involves detailed visual inspection
techniques, simple NDE methods
(MT, PT, UTT) and measurement
tools to determine if more detailed
analysis is required. The components
generally inspected are:
Level II Conditon
Assessment
Based on the fndings observed during
a Level I inspection, more advanced
NDE techniques and sampling are
utilized, which include:
Remote Visual Inspection
Surface Replications
Advanced UT
UTOxide Thickness
WFMT
High Temperature Strain Gages
Hardness/PMI
Metallurgical and Oxide analysis
of Tube Samples
Typical Steam Generators
Level I Conditon Assessment
Performance
Enhancements/
Engineering
Studies
Detailed Visual
Inspection of
Pressure Parts with
Standard NDE
Advanced
NDE
Services
Metallurgical
Examinations
Remaining Life
Assessment
Advanced
Engineering
Analysis
Review Current/
Historical Operational
& Performance Data
Review All
Changes/Updates
to Boiler
Perform Hot and
Cold Walkdowns
Goals
Reliability
Availability
Reduced EFOR*
Managed Risks
Level 1
Level II
Level III
Repeat
Process
Level III Conditon Assessment
When it is imperative to have a comprehensive timeframe
for the remaining life of a component, or when Engineered
Solutions are needed, Advanced Engineering Analysis
should be employed. These services include:
EPRI Remaining Life
Software Tools: TULIP,
BLESS, Creep-Fatigue Pro
Finite Element Analysis
Stress Analysis
Fracture Mechanics
Performance Based
Engineering Studies
CONDITION ASSESSMENT
Program Cycle
Whether your needs are simple or complex, short-term or long-term, Foster Wheeler has the experience and time-tested
technical experts to provide your company with Value Added information and lasting solutions to your problems. To
hear more about how Foster Wheeler can help you meet your Condition Assessment goals, please contact your local
Foster Wheeler Account Representative.
Level 6 > 100%
Level 5 > 80%
Level 4 > 60%
Level 3 > 40%
Level 2 > 20%
Level 1 < 20%
RH Coil Stress Evaluation
*Effective Forced Outage Rate
We offer a full range of steam generator equipment, aftermarket products and services to the power, industrial, and waste-
to-energy sectors. Our global manufacturing and engineering network can deliver cutting-edge products and expertise, quickly and
cost competitively with best-in-class quality. Established in 1891, our experience comes from over a century of designing, servicing,
and continually improving steam generating equipment.
BoilerAssess_Brochure_120811
ARIZONA
Mike Quandt
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T (908) 507-9860
[email protected] COLORADO
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T (636) 326-5108
[email protected] NEW JERSEY
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Account Specialist
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Clinton, NJ 08809
T (908) 713-3226
[email protected]NORTH CAROLINA
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Account Executive
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Charlotte, NC 28226
T (704) 454-8094
[email protected]PENNSYLVANIA
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Account Executive
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Wexford, PA 15090
T (412) 735-4523
[email protected]TEXAS
Larry Oprea
Sr. Account Executive
18222 Hampton Oak Court
Spring TX 77379-6152
T (713) 249-6001
[email protected]www.fwc.com
Paul M. Davis
Commercial Manager
Boiler Condition Assessment Services
55 Maplewood Drive
Pittsburgh, PA 15205
T (412) 327-7420
[email protected]Steam Generators
Circulating Fluid Bed
Pulverized Coal
Oil & Gas
Solar
Bubbling Fluid Bed
Package
Grate and MSW
Metallurgical Waste Heat
HRSG
Environmental Products
Circulating Fluid Bed Scrubbers
Fabric Filters
SCR and SNCR Systems
Low NOx Combustion Systems
Biomass Combustion Retrofts
Coal/Air Control System Upgrades
Plant Operation
Aftermarket Services
Engineered and Replacment
Pressure Parts
Weld Overlay and
Refractory Upgrades
Replacement Parts
Cyclone Burner Retrofts
Coal Mill Service and Upgrades
Boiler and HRSG Maintenance
Outage Construction
Auxiliary Equipment
Condensers
Feedwater Heaters
Biomass Gasifers
