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United Dynamics Corporations Personnel - Raising the Standard Across the Industry
At UDC, our core business is boiler inspection and as with any service basedbusiness, both company name and reputation are defined solely by our staffsexperience, talent, and quality. This is the heartbeat of UDC since inception
some 30 years ago and today remains our business model.
All UDC Field Service Inspectors are full-time salaried employees. It is with strongconviction we understand the retention of inspectors is a key component forsuccess. The distinction of employee retention which is paramount at UDCenables us to sustain and maintain our experienced and highly specialized staff.
No temporary help, general NDE representatives, or inexperienced boilerpersonnel are ever utilized for any inspection. If our schedule is completelybooked and we are unable to staff an inspection project with our certified andexperienced personnel, the work will be declined in order for us to consistentlyoffer our clients nothing less than the highest quality inspection service solutions.
On average, a UDC field services inspector spends 180 to 200 days per yearperforming inspection work for client overhauls. Inspectors provide serviceson 15 to 35 outages annually encompassing a variety of different work scopes,timelines, and boiler designs.
During non-field work time periods, UDC mandates a vigorous training programon multiple platforms for all inspectors. Continuous education and training servesas a key resource for developing our specialized staff. UDC has established arequirement of boiler inspection training which consists of three levels of certification. Our inspectors hold certification through the established
association which sets the industry standard criteria for qualification of best inspection practices.
Safety is priority one at UDC and is treated as such; every inspector operates bythis standard. Simply stated, our safety record is impeccable. Each inspector isOSHA-30 hour trained and compliant. As dictated by procedure, all UDC fieldservice representatives partake in annual respirator fit tests, annual physicalexamination including pulmonary testing, and a bi-annual and/or randomsubstance abuse testing practice.
When you choose UDC, you continually receive repeatable quality, consistency,and uncompromised levels of experience. We ensure that the same projectteam leader (lead man) returns to each and every overhaul accompanied andsupported with a qualified and experienced team of inspectors. This promotesconsistent, accurate, and efficient inspections and builds a strong and trustedworking relationship between plant personnel and UDC staff.
Never compromise..experience the UDC difference!
UDC...Serving the Power Industry since 1979! UDC...Serving the Power Industry since 1979!
Why Select UDC For Boiler Inspections?
The UDC Difference
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United Dynamics Corporation stands firmly behindour recommendations and services. Our priority isquality job performance and customer satisfaction.
COMPANY OBJECTIVESCOMPANY OBJECTIVES
Optimization of Boiler SafetyOptimization of Boiler Safety
Improve Boiler AvailabilityImprove Boiler Availability
Minimize Financial and Generation LossMinimize Financial and Generation Loss
Promote ProPromote Pro -- Active Maintenance Solutions Active Maintenance Solutions
FIVE CORE VALUESFIVE CORE VALUES
ExperienceExperience
ConsistencyConsistency
KnowledgeKnowledge
ScheduleSchedule
Real Time ReportsReal Time Reports
INSPECTION SERVICESINSPECTION SERVICES
VISUAL INSPECTIONS VISUAL INSPECTIONS
Utility Fossil-Fired BoilersHeat Recovery Steam GeneratorsBlack Liquor Recovery Boilers
Waste-to-Energy (Refuse) Boilers
NDE SERVICESNDE SERVICES
Oxide Thickness TestingPhased Array Ultrasonic TestingUltrasonic TestingMagnetic-Particle TestingDye-Penetrant TestingHeader Replications
Certified Weld InspectionsCertified Weld Inspections
Visual Inspections of Auxiliaries Visual Inspections of Auxiliaries
Material Condition AssessmentsMaterial Condition Assessments
Remaining Life AssessmentsRemaining Life Assessments
OTHER SERVICESOTHER SERVICES
Outage ManagementOutage Management
Component Replacement ManagementComponent Replacement Management
EDUCATIONAL TRAINING SEMINARSEDUCATIONAL TRAINING SEMINARS
Boiler Inspection Techniques Level IBoiler Inspection Techniques Level IIHRSG Inspection TechniquesJoint Approach to Boiler Tube Failure PreventionOperators Impact on Boiler Tube FailuresBoiler Inspection Outage Management and Planning
Experience the Difference with POWERFUL Results...Experience the Difference with POWERFUL Results...
Serving the Power Industry Since 1979 United Dynamics AT Corporation 2681 Coral Ridge RdBrooks, KY 40109
(502) 957-7525 Tel
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Experience
UDC field service boiler inspection representatives are more experienced. Each representative at UDC is exposed to 25+ out-ages per year possessing 5 to 10+ years of field service experience.Consistency The same UDC boiler inspection representatives return to your outages. This promotes consistent, accurate, and efficient boilerinspections and builds a strong relationship between plant personnel and UDC staff.
Knowledge UDC services literally hundreds of boilers including a variety of makes, vintages,sizes, and designs. With this exposure, a continuous learning atmosphere is createdand a wealth of knowledge is developed by each and every service representativefrom repair methodology to the latest inspection procedures and technologies. Schedule UDC can conduct a full-scope boiler inspection in a short period of time utilizing alarge and experienced inspection team. UDC routinely accommodates this type of
boiler inspection project for many customers promoting the maximization of plantmaintenance resources and budget. Real Time Reports Throughout the duration of the outage, reports are issued after each component of the boiler is inspected. This creates an environment which limits downtime for skilledlaborers and allows you (the client) sufficient time to review, verify/ order materials,and designate which repairs will be addressed during the overhaul.
Inspection services are UDC's core business.
All repair recommendations through our inspection program areunbiased; based on sound engineering judgment, experience,and quantitative data for justification purposes. An understandingand regard for current plant economic environment is consideredin the evaluation process for every repair recommendation.
UDC services a variety of makes (B&W, CE, FW, Riley Stoker),vintages, sizes (20mw to 1300mw), and designs of boilers. Fossilfuel, waste to energy, and HRSG units are our specialty. AnnuallyUDC performs 80 to 100 boiler inspections on average within thecontinental US and Hawaii. Our portfolio also includes work per-formed internationally in Australia, Canada, China, the DominicanRepublic, Korea, Trinidad, and the Virgin Islands.
Our Five Core ValuesOur Five Core Values
Phased Array Ultrasonic Testing Dye Penetrant Testing
Metallurgical Replications Magnetic Particle Testing
Ultrasonic Testing Oxide Thickness Testing
DC utilizes a variety of basic and special method non-destructivexamination (NDE) techniques to determine material integrity ando perform condition assessments of various boiler components as
well as auxiliary boiler equipment.
ll Field Services Representatives receive NDE training and are testednd certified through UDC NDE procedures which are written in accor-ance with Recommended Practice No. ASNT SNT-TC-1A and ANSI/SNT CP-189.
Serving the Power Industry Since 1979 United Dynamics AT Corporation
2681 Coral Ridge RBrooks, KY 401
(502) 957-7525 T(502) 957-5441 Fa
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UDCs professional field services enable our clients to improve unit availability and alsostreamline scheduled maintenance overhauls. We provide complete documentationas well as an available continuous database of yearly maintenance activities. Overthirty-eight years of in-the-field experience underpins UDC with the knowledge andtools required to assist our clients in preserving time & revenue in their current boiler
maintenance and improvement programs.KEY FEATURESKEY FEATURES
Turnkey planning and management of boiler maintenance outages Complete and thorough boiler and auxiliary equipment inspections Budgeting, Scheduling, and Planning Deployment and utilization of highly skilled inspection personnel Daily interface and documentation for management and contractors Follow -up of all reported work including current status reports Management and coordination of all NDT testing (UT, MT, PT, RT, Replications, etc.) Assessment and documentation of Corrosion / Erosion Rates and/or change in life
assessment Materials Management Current and future outage recommendations
UDC maintains a staff of Certified Weld Inspectors to accommodate any size work scope.
TYPICAL CWI TASKSTYPICAL CWI TASKS
Inspection of welds for conformity and deficiencies (i.e. porosity, excessive penetration, etc.) Verification of base materials and consumable welding materials in conformance to the specifications including the welding
filler metals used for each base material or combination of base materials are as specified Verification of the welding equipment to be used for the work as to appropriateness for use with the welding procedure Verification of the welding procedures as specified and the qualification of the procedure, including that the welding
performed is in conformance to applicable procedure Witness performance and testing of procedure qualification test assemblies Verification of welders, welding operators, and tack welders in regard to qualifications in conformance to the applicable
standards, and qualifications to use the welding procedures specified for the work Witness and/or supervise administration of the welder test assemblies and require re -qualification for welder's whose work
does not conform to applicable standards
UDC creates exact scaled component drawing replications from original component design specifications and drawings indigital format through the use of CAD technology. The drawings produced ensure an easy to read and interpret format.Update services are also available for any drawing produced by UDC to accommodate design changes to existing compo-nents or component replacements.
Key Features Scaled graphic boiler component and side view drawings
Detailed material depiction by specs (Material x OD x MWT) and assigned color coding Field weld lines and DMW lines are illustrated Assembly and tube counts are illustrated Elevations are illustrated Detail of soot blowers, observation and test ports, access doors, and adjacent components are depicted Layering feature allows any material to be viewed separately from the complete component drawing Drawings can be modified to include part or commodity numbers
Serving the Power Industry Since 1979 United Dynamics AT Corporation 2681 Coral Ridge RdBrooks, KY 40109
(502) 957-7525 Tel(502) 957-5441 Fax
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The need for advanced education and training in the area of boiler inspection techniques and methodology continues to be apparent givenincreased regulations, equipment exceeding expected life, sophisticated technology, new testing procedures, new repair philosophy, com-pany downsizing, and industrys aging workforce. Given the variables, UDC created educational seminars designed to cater to t hese needsand provide excellence and expertise in education and training for those who function in all capacities within the industry. Annually, UDCtrains some 600 individuals in the disciplines of Boiler Inspections. Each course offered by UDC is conducted at various locations sponsored
by UDC (public seminars) or a location of your choice (private in-house/in-plant seminars).Boiler Inspection Techniques SeminarBoiler Inspection Techniques Seminar Level ILevel I Our Boiler Inspection Techniques Level I provides a comprehensive overview of boiler history and basic as well as advanced conceptspertaining to overall inspection procedures, failure mechanisms, component and boiler fundamentals, NDT practices, welding procedures,outage preparation, and use of steel and refractory materials. The seminar provides all necessary information to establish and implementan in-house inspection team, clarify appropriate repair procedures, reinforce an existing in-house inspection team, or as a tool to furtherpersonnel knowledge. This seminar is an excellent educational experience for new and experienced personnel alike.
Boiler Inspection Techniques SeminarBoiler Inspection Techniques Seminar Level IILevel II Boiler Inspection Techniques Level II is designed for plant personnel who previously possess some boiler inspection knowledge. Theseminar provides a comprehensive presentation of advanced concepts of inspection procedures, failure mechanisms, component and boilerfundamentals, NDT practices, welding procedures, outage preparation, the use of steel and refractory materials, and introduces basicmetallurgical concepts. The seminar provides the veteran inspector with greater knowledge of inspection techniques and applications, tools
to establish and implement an in-house inspection team, clarify appropriate repair procedures, reinforce an existing in-house inspectionteam, or as a tool for furthering personnel knowledge. This seminar is an excellent educational experience for all levels of plant personnelinvolved with plant maintenance programs and efficiency.
Operator Impact on Boiler Tube FailureOperator Impact on Boiler Tube Failure Operators Impact on Boiler Tube Failure maps a course through cycling of the boiler viewing ramp rates, the failures which stem fromcycling the boiler, and operational upsets and the failures resulting from these upsets. Boiler water chemistry and its importance includingthe failures arising from water chemistry problems are included in the informative discussions. Boiler offline procedures, fill requirements,and applications of steel materials are among the topics covered in the seminar. This seminar raises awareness of the overall impact of operations with techniques and tools to prevent failures from an operational standpoint.
Boiler Outage Management and MaintenanceBoiler Outage Management and Maintenance Boiler Outage Management and Maintenance is designed for plant or corporate personnel involved with coordinating and managing theinspection outage. The overall success of availability and reliability is dependent on the overall success of organization and recorded
compilation of data discovered through inspection and the strategic process of coordinated repair criteria list produced through the outagemanagement team. The seminar will provide tools and procedures which enables the management of inspection outrage utilize the overallprocess for the most productive results possible.
A Joint Approach to Boiler Tube Failure PreventionA Joint Approach to Boiler Tube Failure Prevention A Joint Approach to Boiler Tube Failure Prevention is an insightful presentation examining the positive results of identification of existingconditions within the boiler for prevention of tube failure. The combined efforts of in -the- field inspection and laboratory an alysis of sam-pling tubes or failed boiler tubes provides strategic data for implementing strategic failure preventive maintenance solutions. Some of thetopics include cycling the boiler, operational upsets and resulting damage, quench cracking from water lances/cannons and the strategiesfor approaching these problems. Discussion of the importance of a good water chemistry program, acid phosphate corrosion, caustic corro-sion/gouging, copper deposition, and hydrogen damage, as well as pitting, scale and water side contaminants are part of the presentation.This seminar is a must for maintenance personnel as well as operators and plant managers.HRSG Inspection TechniquesHRSG Inspection Techniques HRSG Inspection Techniques is designed to provide a fundamentals overview and inspection techniques of the combined cycle plant. Thisincludes planning and documentation for advanced online and offline inspections covering external inspection, gas side inspection, waterside inspection, and fire side inspection. The gas side topic will look at gas exposed components such as drums and headers, superheaters,reheaters, desuperheaters, evaporators, economizers, and pre-heaters. Water side and fire side tube failure prevention methods as well asmany case histories are included along with physical samples for the topics covered during the sessions.
Serving the Power Industry Since 1979 United Dynamics AT Corporation 2681 Coral Ridge RdBrooks, KY 40109
(502) 957-7525 Tel(502) 957-5441 Fax
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InspectionReportSample
Gtrack v 3.5.3
Inspection Report Created on 4/26/2010 @ 1:30 PM Page 2 of 10Station: Any Station / Unit #: 1 Report Name: 1-Extended Side Waterwalls
=================================================================================P R I O R I T Y # 1 R E P A I R S
=================================================================================
Action: TUBE REPLACEMENT-P1 Priority #: 1Inspector: Smith J
General location is Left Extended Side Waterwall, At Up-per Arch Intersection
Elevation: 6074'
Cause: Erosion (Fly Ash/ Soot Blower)Appearance: Localized Wall Loss
Tube Material: 2.5" OD x 0.240" MWT x SA-210A1
IK/IR Path: #6
Replace the following left extended sidewall tubes due to remaining wall thicknesses (RWT) at or below65% of MWT:
Tube# (RWT)
T8 (0.108")T9 (0.080")T10 (0.138")T11 (0.143")T12 (0.135")
Upper cut line will be a minimum of 1' up from the floor intersection; lowercut line will be made from the upper dead air space where feasible given thebifurcate arrangement. Fly ash and soot blower erosion are the contributingfactors causing tube degradation.
Due to the difficulty associated with tube replacement in this area (i.e. lackof scaffold for adequate access from upper dead air space, removal of external
lagging and insulation, demo & re-installation of sidewall seal, lead-time onbifurcate tube sections from supplier, limited time remaining during outage forrepairs, etc), alternative repair methods can be employed such as weld restora-tion (pad welding) until tube replacement is feasible.
Ensure that thinned walled welding procedures are employed to include the use of TIG welding if thisalternative repair method is chosen. If replacement is the chosen method of repair, adjacent tubeswhich are eroded and below MWT should be replaced at this time (as detailed on page 3 of this report).Consider the application of weld overlay on new tubing to provide additional erosion resistance.
Work Order: _____________ Status: Inspected
1995-2010 UDC 502 957 7525
Serving the Power Industry Since 1979 United Dynamics AT Corporation 2681 Coral Ridge RdBrooks, KY 40109
(502) 957-7525 Tel(502) 957-5441 Fax
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Tel: 502.957.7525Fax: 502.957.5441
Email: [email protected]
2681 Coral Ridge Rd.Brooks, KY 40109
United Dynamics Advanced Technologies CorporationUnited Dynamics Advanced Technologies CorporationUnited Dynamics Advanced Technologies CorporationUnited Dynamics Advanced Technologies CorporationUnited Dynamics Advanced Technologies Corporation
Department Name Phone - Extension Email
Vice President Field Services Division Jason C. Shankle 502.957-7525 x2207 [email protected]
Manager Sales, Marketing, Education Sherri L. Hart 502.957-7525 x2222 [email protected]
Manager Information Technology Clark Van Kampen 502.957-7525 x2208 [email protected]
Manager NDE Field Services Michael Pannell 502.957-7525 x2223 [email protected]
Manager HRSG Field Services Robert M. Bevilacqua 502.957-7525 x2206 [email protected]
Department Name Phone - Extension Email
Vice President Field Services Division Jason C. Shankle 502.957-7525 x2207 [email protected]
Manager Sales, Marketing, Education Sherri L. Hart 502.957-7525 x2222 [email protected]
Manager Information Technology Clark Van Kampen 502.957-7525 x2208 [email protected]
Manager NDE Field Services Michael Pannell 502.957-7525 x2223 [email protected]
Manager HRSG Field Services Robert M. Bevilacqua 502.957-7525 x2206 [email protected]
Serving the Power Industry Since 1979 United Dynamics AT Corporation
2681 Coral Ridge RBrooks, KY 401
(502) 957-7525 Te(502) 957-5441 Fa
