INSPECTION TECHNIQUES TO

DETECT THE FAILURE OF THE

BOILERS TUBE

February 13, 2015

DINESH POUDEL

Alternative Inspection Techniques to Detect the

Failure of the Boiler Tubes
To:

Mr. Nick Akins

CEO, American Electric Power
1 Riverside Plaza, Columbus, Ohio

From: Dinesh Poudel

Junior Mechanical Engineering Major
Louisiana Tech University
Ruston, LA

Date of Submission: February 13, 2015

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ABSTRACT
In many thermal power plants, failure of boiler tubes causes force outrage. These failures might
cost millions of dollars for big power plants. The main causes for the failure in these tubes are
corrosion inside tube, high temperature, and cracking inside or outside due the over or under
heating of the working fluid. Currently, the most common method is to cut a section of a tube
and insert a probe to detect damages inside the tube. This method is not reliable for inspecting
large numbers of tubes and also causes temporary blockage on the flow of working fluid.
Non-destructive methods of inspection can greatly save money and time for the power plants. In
this report, I have proposed three techniques: spot ultrasound check, crawling robot and a
mecanum magnetic robot. I have compared the effectiveness of these techniques with three
proposed criteria: ingression protection, compactness and vision system, and reliability and
safety. After applying each criteria to each solution, mecanum magnetic robot most closely
adheres to all criteria. Due to its compact size, magnetic wheel that can help stick to the surface
closely, and its easy operation, I recommend a mecanum magnetic robot to be used in the
inspection of the failure of boiler tubes.

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TABLES OF CONTENTS
Executive Summary .......................................................................................................................1
Introduction ....................................................................................................................................2
Purpose.....................................................................................................................2
History of the Problem .............................................................................................2
Recent Studies of the Problem .................................................................................2
Recent Studies of the Problem ........................................................................................... 3

Inspection Technique to Detect Boiler Tube Failure .................................................................4

Proposed Solutions ............................................................................................................. 4

Spot Check Ultrasound ................................................................................4

Crawling Robot ............................................................................................5
Mecacum Robot ...........................................................................................5
Explanation of Criteria .............................................................................................6
Compactness and Vision System .................................................................6
Ingress Protection.........................................................................................6
Reliability and Safety...................................................................................7
Application of Criteria to the Solutions ...................................................................7
Applying First Criteria to Solutions .............................................................7
Applying Second Criteria to Solutions ........................................................9
Applying Third Criteria to Solutions ...........................................................9
Conclusions ..................................................................................................................................12
Overall Best Solution/Recommendation ...................................................................................13
Bibliography ................................................................................................................................14
Work Cited .............................................................................................................14
Work Consulted .....................................................................................................16
Appendices ....................................................................................................................................17

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LIST OF FIGURES
Figure 1.

Header Tube and Feeder Tube .................................................................................3

Figure 2.

Ultrasound Testing Procedure..................................................................................4

Figure 3.

Lateral and Mainline Probe II ..................................................................................5

Figure 4.

Pipe Inspection Robot ..............................................................................................6

Figure 5.

Ultrasound Testing in the Boiler Tubes ...................................................................7

Figure 6.

Lateral Movement of Robot inside the Tubes .........................................................8

Figure 7.

Close up of Communication Module ......................................................................8

Figure 8.

Thickness Result of Ultrasound Testing ...............................................................11

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LIST OF TABLES
Table 1.

Technical parameters of Vertical Climbing Robot ...............................................10

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EXECUTIVE SUMMARY
During the annual shutdown of any power plant, more preference is given to maximize the plant
inspection coverage while minimizing the plant down time significantly. Boiler tube inspection
is one of the important regular activities in the thermal power plants. Currently, after the plant is
shutdown, a high pressure water jet is used for removing the deposition of any unwanted
materials inside the tube. Thereafter, boiler tubes are inspected using the conventional ultrasonic
technique or inserting a probe through the hole. These techniques have limited use and reliability
because they require more time and cannot cover all the areas that are to be inspected.
The lack of a proper technique to inspect the boiler tubes causes boiler tube failure, which in turn
causes outages in many thermal power plants. The problem related with boiler tube failure has
caused a huge amount of revenue loss in the recent years. Determining the boiler tube thickness
using non-destructive techniques is a primary concern to stop such outages in the thermal power
industry.
In this report, I proposed three non-destructive methods: spot check ultrasound, crawling robot
and mecanum magnetic robot. I have also proposed three criteria: compactness and vision
system, ingression protection, and reliability and safety. Each solution is then compared with
each criteria.
Based on my research, a mecanum magnetic robot most closely adheres to the given criteria. Its
compact size provides a flexibility to use this kind of robot in really small boiler tubes and
covers large sections under inspection. The vision system is integrated with four modules, the
locomotion module, the energy module, the control and communication module, and the visual
inspection module (Schoeneich 1). This method provides an excellent video feed during
inspection. Additionally, their magnetic wheels make it easy to stick to the surface of the tubes
and make it easy to take turns even at the small curvature inside the boiler tube.

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INTRODUCTION
Purpose
Boiler tube failure has been a main reason for outages at many thermal plants. The effects of
temperature, corrosion, erosion, oxidation and combustion of products causes degradation of
tubing steel which significantly reduces the tube wall thickness and results in failure of the tubes
many years before tubes expected service life(Park et al.1883). To prevent untimely boiler tube
failure, many power plants need non-destructive method (NDT) to inspect boiler tube. In this
report, I will propose three solutions: spot check ultrasound, crawling robot, and mecanum robot.
I will also present three criteria: compactness and vision system, ingress protection, and
reliability and safety. I will then apply each criteria to each solution and recommend the overall
best solution to the problem.

History of the Problem

Many thermal power plants use boiler tubes, which use water or other liquid or gas as a working
fluid. The tubes are then heated by external flame or hot gas from the furnace. This heated
working fluidoften called superheated steamis used to operate many engines to produce
energy (Ley et al. 450). Regular maintenance and inspection of these boiler tubes is essential for
the regular production of energy which then can be used in many other forms. This activity
should be cost effective. These tubes are prone to failure from corrosion and cracking (both
inside and outside of the pipe), and may cause the product to leak and the working fluid to under
or overheat. Thermocouple, are the commonly used device to inspect at the single point.
However, these thermocouple cannot cover all of the area at a time. Also, the inspection ports,
made on the tube itself, provide the view of the internal portion, but the flowing working fluid
and flames obscure the visibility of the equipment while it is operating (Park et al. 1882).

Recent Studies of the Problem

According to Dr. Ardene L. Moore, Professor of Mechanical Engineering at Louisiana Tech
University fouling (the collection of unwanted material on the surface of the tubes) is the main
reason of boiler tube failure in the United States. It can occur when hydrocarbons (i.e. natural gas
or petroleum) are the working fluid .The primary concern on the maintenance aspects of the
boiler system is the corrosion fatigue to the feeder tubes. The asymmetric expansion and
contraction of the boiler tubes, due to the hot steam flow, develops corrosion fatigue cracks
inside the feeder tubes over time. If left neglected, such cracks can develop further and lead to
disastrous results for the company and its operations (ASME Section 7 10).
Currently, a section of the feeder tube is removed in order to create an insertion point for the
boroscope camera (as indicated by the red arrow in Figure 1). Considering the scale and total
number of feeder tubes that require attention, such inspection methods can be expensive and time
consuming. Therefore, an alternative inspection method is proposed that utilizes the hand-hole
as an entry point for the inspection camera (as indicated by the green arrow in Figure 1).

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Figure 1. The red arrow represents the current inspection strategy. The green arrow
represents the new, proposed inspection strategy
Currently, a section of the feeder tube is removed in order to create an insertion point for
the boroscope camera (as indicated by the red arrow in Figure 1). Considering the scale
and total number of feeder tubes that require attention, such inspection methods can be
expensive and time consuming. Therefore, an alternative inspection method is proposed
that utilizes the hand-hole as an entry point for the inspection camera (as indicated by
the green arrow in Figure 1).

Research Procedure
The primary research included interviews with Dr. Ardene L.Moore, Mechanical
Engineering Professor at Louisiana Tech University, Engr. Indu Sharma, Mechanical
Engineer at Toyota USA, and the field research to AEP plants at Shreveport, Louisiana,
where I got the chance to see the actual head tube and feeder tube and their complex
configuration in the plants. Secondary research included the study of books on Boiler
Tubes topic found in the Prescott Memorial library of Louisiana Tech University,
engineering journals obtained from Engineering Village 2, and some articles from
website of the specific company directly.

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ALTERNATIVE INSPECTION TECHNIQUES TO DETECT

FAILURE OF BOILER TUBES
Solution
Currently, a section of the feeder tube is removed in order to create an insertion point for the
boroscope camera or conventional ultrasound testing is done for boiler tube testing. Both of these
methods are not feasible methods for inspecting large number of boiler tubes and sometimes
whole power plant might have to shut down which is not in the favor of company itself. So, I
have come up with three other non-destructive alternatives.
Solution 1: Spot Check Ultrasound
Spot Check Ultrasound is the traditional method to inspect tubes. It is performed on the outside
diameter of the tubes and is limited to certain parts of the tube which are easily accessible and
visible to humans. However, it leaves large portion of the testing area untested. This process is
considered nondestructive, which permits the quick and reliable measurement without requiring
both sides of the tubes. The ultrasound instruments have a dual element transducer (or dual
probe): one for transmitting the impulse of ultrasonic sound and one for receiving the reflected
sound. Acoustic impedance of solid metal differs from that of fluids, gases, and corrosion
products. Hence, the transmitted sound pulse is reflected from surface of the remaining metal.
The wall thickness is calculated by multiplying the half of the time taken for two way transit
with the velocity of sound in that specific material (Sullivan 64).

Figure 2. Ultrasound Testing Procedure. (Google. N.p., n.d. Web. 05 Feb. 2015.)

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Solution 2: Crawling Robot

The primary component of this inspection device is a robotic rover. The rover acts as a
boroscope camera guidance device. Figure 2 shows a robotic pipe inspection device
manufactured by CUES. The second component of the device is a lateral insertion assembly
attached to the front end of the rover (CUES 1). The assembly directs the video probe to the
desired feeder tubes.

Figure 3. Lateral and Mainline Probe II. (CUES Inc. N.p., n.d. Web. 20 Jan. 2015.)
The Parent rover performs its duty by navigating through the header and deploys the camera
probe into the desired feeder tube. The deploying mechanism of the parent robot can be rotated
to guide the probe into appropriate feeder tubes. The umbilical cord from the device will provide
the user with necessary telemetry and video feed.
Solution 3: Mecanum Wheel Robot
Design 3 is a robotic inspection device that can be driven along a steel surface using magnetic
wheels. The tiny rover can be inserted without the assistance of any parent rover. The compact
size and magnetic wheels allow the user to drive the rover through the header to locate and
inspect the desired feeder tubes. Figure 3 shows the superior maneuverability of the robotic
inspection device built by Honeybee Robotics.
The unique characteristic of the rover is that the robot has magnetic Mecanum wheels. The
magnets allow the lightweight robot to adhere to the steel surface and provide extreme
maneuverability and traction. A camera attached to the rover will be able to transmit videos to
the operator for inspection purposes. The Mecanum wheels built with magnets allow the robot to
move to any direction without having to turn its body. This capability provides the design with
extreme maneuverability in tight spaces such as pipes ("Pipe 1).

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Figure 4. Pipe Inspection Robot. (Honeybee Robotics. N.p., n.d. Web. 20 Jan. 2015.)
The unique characteristic of the rover is that the robot has magnetic Mecanum wheels. The
magnets allow the lightweight robot to adhere to the steel surface and provide extreme
maneuverability and traction. A camera attached to the rover will be able to transmit videos to
the operator for inspection purposes. The Mecanum wheels built with magnets allow the robot to
move to any direction without having to turn its body. This capability provides the design with
extreme maneuverability in tight spaces such as pipes ("Pipe, 1).

Criteria
In todays competitive industrial world time, cost, and efficiency of any machine are a major
subject of concerns.
Compactness and Vision System
The device should be compact enough to negotiate through tight spaces. Though the length of the
device is open for consideration, the cross-sectional area of the device should be small enough to
fit through boiler header dimensional constraints. The device should have a vision system that
can transmit and record videos for documentation and navigational purposes. The device should
be able to identify and display the geometric coordinates of the point of inspection. It will be
preferable for the user to have control over the cameras orientation (Park et al. 1881).
Ingress Protection
As one of the key requirements of the design process, the device should be rugged enough for
use in an industrial setting. It is preferable to have ingress protection against solids and liquids
for exposure limits that are common inside the boiler headers and tubes (Ley et al 503).
Ingression rating usually has three components: protection from solid objects or materials,
protection from liquid, and protection from mechanical failure.

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Reliability and Safety

The device should be reliable for extended use with limited maintenance. In case of parts failure,
components should be easily retrievable and replaceable. No parts should come loose from the
unit because it would require search and retrieval. The device should be safe during its
operational life. For instance, the device should not have any sharp edges or harmful wireless
radiation associated with the device (Occupational Safety and Health Administration 6).

Applying Compactness and Vision System to the Solutions

Compactness and Vision System -- Spot Check Ultrasound
In large power plants, thousands of boiler tubes need to be tested or inspected. Although, the spot
ultrasound check method is very easy to implement, its uses are limited to the human accessible
sites or areas only. Large resources and a huge workforce are required to inspect these large
number of tubes. So, lots of boiler tubes sections are left untested.
An ultrasonic transducer and probes can be used in time, frequency, and image domains. Time
domain measures the time of flight and velocity of the ultrasonic sound, and this information is
used by computer to measure the thickness of the tube wall and the size of the deposition inside
the tube (Bhowmick).The integrated system of transducer and analyzer makes up the excellent
vision system while analyzing failure of boiler tube.

Figure 5. Ultrasound Testing on the Boiler Tubes. (Google. N.p., n.d. Web. 29 Jan. 2015.)
Compactness and Vision System Crawling Robot
A crawling robot has a secondary section with a video probe, which provides the video feed
along with the coordinate of its position. Its size is compact enough to make turn backward and
forward inside the feeder tubes. The user can watch the section of tube on the computer screen
while controlling robots motion to the desired location. This robot with 10kg of weight has
overall dimension of 420mm *320mm. This robot has difficulty testing curvature of the tubes
due to its restricted mobility-either forward or backward. That robot gets blocked in lateral and
down ones. Thus, this robot has difficulty testing curvature of the tubes due to its restricted
mobility-either forward or backward.

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Figure 6. Lateral Movement of Robot inside the Tubes. (Schoeneich, Patrick. Lateral
Movement of Robot inside the Tubes. N.p., n.d. Web. 9 Feb. 2015.)
Compactness and Vision System Mecanum Wheel Robot
The Mecanum robot has magnetic wheels and is able to move in 25 mm of diameter
ferromagnetic tubes in any inclination, and able to pass curves of 150mm curvature in some
cases (Schoeneich). The helical magnetic wheels make its size compact, giving small clearance
inside the boiler tube.
Four modules are used to control mecanum robot: the locomotion module, the energy module,
the control and communication module, and the visual inspection module (Schoeneich). The
integration of these four modules collectively provides the best video feed during the inspection
process in the power plants (Schoneich).

Figure 7. Close up of Communication Module. (Schoeneich, Patrick. Close up of

Communication Module. N.p., n.d. Web. 10 Feb. 2015.)

Conclusion
During the annual shutdown of any power plants, the main emphasis is given to maximize
coverage of the boiler tube inspection and minimize the plant shut down time. According to
Engr. Indu Sharma, Mechanical Engineer at Toyota USA, the internal diameter and the degree

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of curvature are the major factors to be considered while designing the robot. Hence, the
Mecanum wheel Robot works the best when judged by the first criterion. Its compact size,
maintained by helical magnetic wheels and four integrated modules to provide best video system,
helps to inspect the each and every corner of the boiler tubes in the power plants in the least
possible amount of time (Badodkar, 32).

Applying Ingress Protection to the Solutions

Boiler tubes in thermal power plants are used in hot corrosive environment; hence, they require
protection from solid, liquid, and mechanical failure for the smooth function of the power plants.

Ingress Protection Spot Check Ultrasound

Spot check ultrasound is used from the outside of the boiler tubes, hence, there is no concern for
the ingress protection in the dry air (as a working environment). However, the reflection of the
transduced sound depends on the working fluids state and surrounding composition of the air,
and it might reduce the effectiveness of Ultrasound Testing during the inspection process.
Ingress Protection Crawling Robot
The parts of the robot include rubber and some light metals, like aluminum, steel and iron. This
metals are prone to rusting and corrosion. But, now a days, many coating compound are used to
protect them from rusting. Nevertheless, the motor and the system itself are also prone to some
ingression.
Ingress Protection Mecanum Wheel Robot
This robot has a compact shape to provide the better grip on the surface. Mecanum Robot can be
used from outside or inside the tube which gives more resistive power towards the ingression
when used on the outside diameter. Nevertheless, the magnetic wheels are prone to rusting. It can
have the same problem of ingression like the crawling robot.
Conclusion
Both Mecanum Robot and crawling robot are prone to the ingression when used inside the
working fluid. This limits their usability when compared with the ingression resistance. On the
other hand, there is no concern related with ingression on Spot Check Ultrasound method, so,
Spot check ultrasound seems to work the best when judging with the second criterion. High
temperature/high reliability materials and electronics are also the key factors related with
ingression of the robot. Hence, Dr. Moore also suggested that use of Ceramics or high T
refractory metals on robots can greatly reduce the problems associated with ingression.

Applying Reliability and safety to the solutions

Reliability and Safety Spot Check Ultrasound
This inspection method requires surface preparation and use of a couplet between UT probe and
the tube (Bhowmick 97). It can be used both at distance and in contact from the surface. This

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feature is very important in cases where surface contact is not available due to the deposition in
boiler tubes. However, certain parameters which are vital while implanting this method includes:
Surface nature & topography of the test piece.
Surface temperature of the test piece.
Chemical nature of the surface and the couplant to prevent any type of chemical reactions,
corrosion etc.
Whether any pre surface preparation like cleaning etc. is required or not (Bhowmick 98).
Also, this technique is limited to few localized places for tube thickness measurements
(Badodkar 32). Spot Check Ultrasound takes a long time and manpower to inspect a section of
boiler tubes. In addition, a person carrying out the inspection may have some health related
issues when getting himself in a radiation area for a long time.
Reliability and Safety Crawling Robot
Crawling robot are safe to use, since person can control the position and monitor the video feed
from any distance. Table 1, provides the typical parameters of the crawling robot. The 10 kg of
robot has maximum of 120 mm/sec of speed. This is cost effective too. This robot has a rubber
tire which might cause slippage inside the tube. Additionally, its length is long which might
cause its mechanical failure inside the boiler tubes.

Table 1. Technical parameters of Vertical Climbing Robot. Badodkar, D. N. "EMAT Integrated

with Vertical Climbing Robot for Boiler Tube Inspection." Proceedings of the National Seminar
& Exhibition on Non-Destructive Evaluation (2009): 32-36. Web. 13 Feb. 2015

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Reliability and Safety Mecanum Wheel Robot

The Mecanum Wheel Robot has a magnetic tire which can stick to the surface tightly providing
the good grip. This tight gripping provides the user with a better section view. Also, its size is
compact and magnetic; hence, there is less chance for mechanical failure. Larger number of
tubes can be inspected in less time and more conveniently.
The Mecanum Wheel Robot can measure Pitch-catch sensor alignment and tube thickness with
an accuracy of 0.127 mm. Scanning up to 500 mm/sec is possible with the special couplant
(special surface) preparation. This provides large inspection coverage in the least amount of
time. Attached control module provides the geometry of the location of the robot, which helps in
creating the plot of wall thickness with time. This wall thickness mapping date information can
be used to estimate the boiler life. It works on 240volts, 50Hz power supply and consumes total
electric power of less than 2KW (Badodkar et al. 34).

Figure 8. Thickness Result of Ultrasound Testing. (Bhowmick, S. Thickness Result.

International Journal of Engineering Research and Technology, 2011. Web. 13 Feb. 2015.

Conclusion
Compact climbing robots have been already used successfully to substitute the expensive and
time-consuming process of scaffolding; the idea to use this technology also in power plant
inspection seemed straightforward. It is cost effective, reliable, and safe to use in the inspection
of the boiler tubes. Hence, Mecanum Wheel Robot is the best when judged by the third criterion.

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CONCLCUSIONS
During the annual shutdown of any power plants, the main emphasis is given to maximize
coverage of the boiler tube inspection and minimize the plant shut down time. This inspection
method requires surface preparation and use of a couplant between UT probe and the tube. As a
result, this technique is limited to few localized places for tube thickness measurements. Hence,
Mecanum wheel Robot works the best when judged by the first criterion. Its compact size
maintained by helical magnetic wheel and an integrated four modules to provide best video
system helps to inspect the each and every corner of the boiler tubes in the power plants in least
possible time (Badodkar 32).
Both the Mecanum Robot and the crawling robot are prone to the ingression when the used
inside the working fluid. This limits their usability when compared with the ingression
resistance. On the other hand, there is no concern related with ingression on Spot Check
Ultrasound method, so, Spot check ultrasound seems to work the best when judging with the
second criterion.
Compact climbing robots have been already used successfully to substitute the expensive and
time-consuming process of scaffolding; the idea to use this technology also in power plant
inspection seemed straightforward (Siegwart 4). Hence, Mecanum Wheel Robot is the best when
judged by the third criterion. It is cost effective, reliable and safe to use in the inspection of the
boiler tubes.

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RECOMMENDATIONS
Power plants and similar facilities have to be inspected regularly for maintenance and security
reasons. Automating this task using mobile robots can decrease the total inspection time and
even allow for reaching areas that were inaccessible with conventional methods. Thus, there is a
great potential for both increasing the inspection quality and simultaneously decreasing
inspection costs and time. As the business of inspecting power plants is very profitable, new
innovations in this field bring significant economic benefits (Siegwart 6).
Mecanum Robot closely adheres to our established criteria above. Hence, I recommend for
power plants (having boiler tubes) to use Mecanum Robot to inspect the boiler tubes due to the
following reasons.
1. This robot provides the close view of the section of boiler tubes and is compact enough to
move through small cross section of boiler and feeder tubes.
2. This method reduces the extensive use of manpower and time taken to inspect tubes in
power plant( this task might be dangerous to the humans)
3. It removes the traditional method of cutting the section a tube to inspect and helps
avoiding extra cost for fixing such tubes. Hence, it will provide both employees safety
and profit for the company.

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BIBLIOGRAPHY
Work Cited
ASME Section 7. International Boiler and Pressure Vessel Code, Care of Power Boilers,
American Society of Mechanical Engineers. ASME, 2014. Web. 19 Jan.2015.
Badodkar, Singh, et al. EMAT Integrated with Vertical Climbing Robot for Boiler Tube
Inspection. Division of Remote Handling &Robotics (DRHR) (2009):32-36.Academic
Search Complete. Web. 05 Feb.2015.
Bhowmick, S. "Ultrasonic Inspection for Wall Thickness Measurement at Thermal Power
Stations." International Journal of Engineering Research and Technology 3154.4(2011):
689-107. Academic Search Complete. Web. 30 Jan. 2015.
CUES Lateral and Mainline Probe II." CUES Inc. N.p., n.d. Web. 17 Jan. 2015.
Ley, Obulia, et al. Automating Data Analysis During The Inspection Of Boiler Tubes Using
Line Scanning Thermography. AIP Conference Proceedings 1430.1(2012): 499-506.
Academic Search Complete. Web. 18 Jan.2015
Moore, Ardene. Personal interview.11 Feb.2015
Occupational Safety and Health Administration. Electric Power Generation, Transmission, and
Distribution. U.S. Department of Labor, Occupational Safety and Health
Administration. OSHA, 2012. Web. 18 Jan.2015.
Park, Sangdeok, et al. Development of Mobile Robot Systems for Automated Diagnosis of
Boiler Tubes in Fossil Power Plants and Large Size Pipelines. IEEE Conference
Proceedings

(2012):1881-1885.Academic Search Complete. Web. 16 Jan.2015.

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"Pipe Inspection Robot | Honeybee Robotics." Honeybee Robotics. N.p., n.d. Web. 13 Jan. 2015.
Schoeneich, Patrick, et al. Tubulo- a train-like miniature inspection climbing robot for
ferromagnetic tubes International Journal of Electromagnetics and Electronics (2012):1
5. Academic Search Complete. Web. 16 Jan.2015.
SIEGWART, Roland, et al. Design of compact climbing robots for power plant inspection.
Research Institute of Industrial Science and Technology (2010):1-174.Academic Search
Complete. Web. 25 Jan.2015.
Sharma, Indu. Personal interview.10 Feb.2015
Sullivan, Ed. "Integration Of Ultrasound Tool Promotes Power Plant Health." Power
Engineering 113.3 (2009): 64. Military & Government Collection. Web. 22 Jan. 2015.

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Work Consulted
Albina, Dionel. THEORY AND EXPERIENCE ON CORROSION OF WATERWALL AND
SUPERHEATER TUBES OF WASTE-TO-ENERGY FACILITIES. Department of
Earth and Environmental Engineering. (2005):25-50Academic Search Complete. Web.
08 Feb.2015.
Bakhtiari, Sasan, D. S. Kupperman, and W. J. Shack. Assessment Of Noise Level For Eddy
Current Inspection Of Steam Generator Tubes. [Electronic Resource]. n.p.: Washington,
DC : U.S. Nuclear Regulatory Commission, Office of Nuclear Regulatory Research,
[2009], 2009. Louisiana Tech University. Web. 03 Feb. 2015.
"Boiler Tube Inspection Camera." Mechanical Engineering 115.7 (1993): 40. Military &
Government Collection. Web. 10 Feb. 2015.

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APPENDICES
Interview with Dr. Ardne L. Moore
(Dr. Moore is a Professor of Mechanical Engineering at Louisiana Tech University)
1. In your view, what are the major causes of tube failure? And, what might be the state of
this problem in USA?
Answer: Fouling is the collection of unwanted material on the surface of the tubes. It can
occur when hydrocarbons (i.e. natural gas or petroleum) are the working fluid. Oil and
gas industry are facing problem due to the failure of tubes by oxidation and corrosion.
2. We should consider the extreme working conditions in the power plants (it might be hard
to stay there for longer time to inspect pipe since they are maintained at very high
temperature). Out of three solution proposed above, which one would be the best in the
large industry with thousands of pipes to be inspected?
Answer: Mecanum Magnetic robot seems more reasonable and practical. Their
integrated communication modules are best for providing good video feed.
3. What kind of materials should we use to build the robot to protect against ingression?
Answer: Ceramics or high T refractory metals can greatly reduce the problems
associated with ingression.
4. Since Manucum robot can only work on magnetic surfaces? Are all the boiler tubes made
of ferrous alloys?
Answer: Not all the tubes are made of ferrous alloys. Coating is done on the surface to
provide great strength and protect from ingression.
5. What criteria do you think would be most appropriate to apply to this problem?
Answer: High temperature/high reliability materials and electronics.

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Interview with Engineer Indu Sharma

(Indu Sharma is an Engineer at Toyota USA in Ann Arbor, Michigan)
1. How does the working principle of Ultrasound Spot check and mecanum robot differ?
Answer: Ultrasound has transducers one for giving pulse of sound and one for receiving.
It can be performed from outside diameter and analyzed to get the exact thickness of the
tubes.
2. Out of the solutions I have provided above, which one would be more cost effective in
long term?
Answer: Either crawling robot or mecanum robot should be cost effective and more
reliable for long term. And, this is because they can inspect large number of tubes than
using the ultrasound testing method.
3. What physical constraints should we consider while choosing the robot for inspection?
Answer: The internal diameter and the degree of curvature are the major factors to be
considered while designing the robot. Various power plants use various types of tubes.
4. Which solution would recommend the most?
Answer: I would recommend either crawling or mecanum robot. But, considering the
magnetic capacity and compact size, mecanum robot has more potential for future.