RESIDUAL LIFE ASSESSMENT STUDY REPORT

TCR ARABIA COMPANY LIMITED

FOR
Report No.:
TCR/002/10/RLA
MS LINE, LTSH AND HTSH
KINGDOMHEADER, LTSH AND HTSH
OF SAUDI ARABIA TUBES OF
Date: 01.02.2010

PHASE 1 - UNIT # 5 BOILER

CLIENT: SALINE WATER CONVERSION CORPORATION Page No.1 of 145

SALINE WATER CONVERSION CORPORATION (SWCC, Jubail)

KINGDOM OF SAUDI ARABIA
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
KINGDOM OF SAUDI ARABIA Date: 01.02.2010

CLIENT: SALINE WATER CONVERSION CORPORATION

TABLE OF CONTENTS

Chapter
No.
Contents Page No.

1 Foreword 1
1.1 Team members 2
2 Executive Summary 3–5
3 Boiler design and history 6
4 Damage mechanisms 7–9
5 Various Techniques/methodology for residual life assessment of Boiler 10 – 12
6 Introduction to Non-Destructive Tests 13 – 16
7 Key Observations & Findings 17 – 18
8 Analysis of findings and judgment on Remaining life Assessment 19
9 Recommendations 20
Annexures
A Laboratory Testing Of High Temperature Super heater Tubes 21 – 40
B Microstructure and SEM Reports 41 – 109
C Hardness Reports 110 – 126
D Magnetic Particle Inspection Reports 127 – 137
E Ultrasonic Testing Reports 138 – 142
F Thickness Measurement Reports 143 – 146
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page 1 of 146

1. Foreword
Power plant owners may want to operate their plants safely, reliably and profitably for as long as
possible. Standing in way of this, however, is not only the ageing process of the materials used, but
also ongoing technical developments, which create ever more profitable and environmentally
tolerate production processes.

Boiler pressure parts like super heater tubes, steam pipes and headers are operating in the creep
range are designed for a certain minimum lifetime. These components deteriorate continuously
during their service as a result of time dependent material degradation process like creep, fatigue,
corrosion and oxidation. In actual practice material damage results from interaction between two or
more of these mechanisms, causing unanticipated failures. Such failures may be catastrophic in
nature and may lead to huge loss.

It has been observed by the utilities that the useful life of components in service may well exceed or
fall significantly short of the designed life based on its operational, metallurgical, design and
manufacturing conditions. Sometimes-premature failures occur due to unforeseen system stresses
and stress concentrations, temperature excursions, cycling, corrosive and erosive environments.

Looking to above situation, utilities were globally showed interests for ageing power plants to assess
the residual life of equipment particularly for those components operating in the creep range.

In view of the above M/s TCR Arabia company Ltd was entrusted for Residual Life Assessment of the
MAIN STEAM LINE, LTSH and HTSH header, LTSH and HTSH tubes of Boiler unit # 5 at SWCC, Jubaili
through microstructure degradations aspect as major criteria along with other conventional NDT
method to judge the flaws or defects present at main weld joints. In addition to these three tubes
representing HT super heaters were removed and subjected for metallurgical assessments through
microstructure and mechanical properties.

This report details the study conducted, the relevant data, observations, analysis and
recommendations component-wise. Recommendations for continued economical operation of the
boiler are also mentioned.

We would like to place on record our appreciation and thanks to the excellent co-operation, support
and assistance extended by the executives and staff of M/S SWCC, Jubail thus ensuring timely
completion of RLA site activities.
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page 2 of 146

1.1 TEAM MEMBERS

 The team members involved in RLA of Boiler Components of Phase I, Boiler # 5, SWCC, Jubail

TCR Arabia Members

 Mr. V.K. Bafna (Chairman – TCR Group)

 Mr. P.U. Haribhakti (Director –TCR Arabia)

 Mr. Rohit Bafna (Director – Global sales)

 Mr. Syed Ameen Hassan (Country Manager, TCR Arabia)

 Mr. S.K. Patra (NDT level-III –RT, UT)

Site Engineers / Technicians:

 Mr. Rizwan Desai (Project Incharge)

 Nagesh Tambade (NDT Level II)

 Gaurange Gore (Metallographer)

 Vishal Jaiswal (NDT Level II)

 Mohammed Ehsanulla (NDT Level II)

 Laxmikant (NDT Level II)

 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page 3 of 146

2. Executive Summary
Name of the Test performed
Sr.No. Major findings Recommendations
component as per scope
01 Main Steam a)WFMPI WFMPI was performed Microstructure under optical as well
Pipe b)In-situ on butt joints, no as SEM indicates initial level of
Metallography significant indications degradation in terms of initial level of
c)Ultrasonic were observed. oriented creep cavities at replica
examination No significant defect locations 1,2,3,5,8, 12 and isolated
d)hardness observed in Ultrasonic creep cavities at other replica
examination of butt locations, thus indicating good
weld joints. remaining life of these components
Microstructure studied from microstructure degradation
at the weld/HAZ and point of view. The Main steam Pipe
parent metal indicates Line can be used for further
initial level of creep operation. It has useful remaining life
damage. of more than 44000 hours provided
it is operated under the O&M
guidelines given by the original
equipment manufacturer. It is
recommended to monitor after
interval of 26000 hours. It is
suggested to carry out thorough RLA
assessment of steam pipe line after
interval of 44000 hours.
02 HTSH HEADER a)WFMPI WFMPI was performed Microstructure under optical as well
b)In-situ on butt joints, no as SEM indicates initial level of
Metallography significant indications degradation in terms of initial level of
c)Ultrasonic were observed. isolated creep cavities, thus indicating
examination No significant defect good remaining life of these
d)hardness observed in Ultrasonic components from microstructure
examination of butt degradation point of view.
weld joints. It has useful remaining life of more
Microstructure studied than 88000 hours provided it is
at the weld/HAZ and operated under the O&M guidelines
parent metal indicates given by the original equipment
initial level of creep manufacturer. These headers are
damage. recommended for re- inspection after
44000 hours of operation.
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page 4 of 146

Name of the Test performed as

Sr.No. Major findings Recommendations
component per scope
03 HTSH TUBES a) In situ The microstructure shows All tubes displayed initial level of
metallography spherodization of pearlite creep degradation in terms of
and hardness and effect of spherodization of pearlite.
b) Destructive decarburization. Presence However those tubes removed
testing like of isolated cavities is and subjected for lab
tensile, hardness, observed with in-situ metallography, did not show any
microstructure metallography presence of creep cavities at the
and scale examination. Laboratory grain boundaries.
measurement testing shows that tubes Laboratory testing
analysis. confirm to required There is a presence of micro
specifications with respect pitting and inter-granular cracks
to mechanical properties at OD but it is about one grain
and did not reveal deep which does not indicate
significant presence of immediate concern. The scale
creep damage. thickness at ID is in the range of
150-300 microns; indicating the
overall condition of tube having
higher internal scale.
EDS analysis at ID scale indicates
the presence of Copper and
Nickel, which indicates that there
is a possibility of leakage in the
condenser and contaminated
water could have entered in
boiler. It is recommended not to
run the boiler with condenser in
leakage condition.
It is suggested to carry out
inspection of these HTSH tubes
after 26000 running hours i.e.
after three years.
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page 5 of 146

Sr.No. Name of the Test performed as Major findings Recommendations

component per scope
04 LT HEADER a) WFMPI No significant LTSH outlet header is in
b) In-situ damage/degradation good condition and can be
Metallography observed continued for further
c)Ultrasonic operation. It has useful
examination remaining life of more than
d) hardness 88000 hours based on creep
damage, provided it is
operated under the O&M
guidelines given by the
original equipment
manufacturer. This header
is recommended for re
inspection after 44000
hours of operation.
05 LTSH TUBES a)In-situ The microstructure shows LTSH tubes show initial level
Metallography and spherodization of pearlite of degradation in the
hardness. and effect of microstructure examination.
decarburization. Presence It can be continued in the
of isolated cavities is service for 44000 hours,
observed with in-situ provided it is operated
metallography under the O&M guidelines
examination. given by the original
equipment manufacturer.
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page 6 of 146

3. Boiler Design & History Details

3.1 BOILER DESIGN DETAILS

Supplier and Manufacturer : M/s I.G.E.- FRANCO TOSI-ITALY

Year of Commissioning : 1982
Boiler Type : Vertical Unit Pressurized
Type of circulation : Natural circulation
Steam capacity at MCR : 300 T/Hr
Steam Drum Pressure : 66 Kg/cm2
Steam temp. at SH-I (O/L), °C : 370 °C
Steam temp. at LTSH- (I/L), °C : 313 °C
Steam temp. at LTSH- (O/L), °C : 450 °C
Steam temp. at HTSH- (I/L), °C : 407 °C
Steam temp. at M.S.S.V. °C : 513 °C
Type of fuel fired : Natural Gas

3.2 BRIEF HISTORY OF BOILER:

Boiler was commissioned in 1982.

Operating hours up to 2009 is 157695 hours.

No. of tripping - 88

Replacement History: During May 2003 outage, the 1st front tube in model 20 HTS super heater coils,
were replaced due to distortion. Also, a rehabilitation repair project is going on during this October

Failure History: Distortion in first front tube observed in 2003 as reported in replacement history.
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
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4. Damage Mechanisms

Damage to Pressure Parts in a boiler can arise due to the following factors:

1. Operation related:

 Creep related damage due to operational temperature and pressure

 Fatigue damage due to mechanical stresses

 Thermal fatigue damage due to improper insulations

2. Material related:

• Selection of original materials

• Manufacturing defects and incoming inspection of original materials

• Replacements made whether in accordance with OEM guidelines

3. Fabrication related:

• Quality of welds and rivets

• Quality of heat treatment adopted after welding

Following is the list of Metallurgical damage mechanisms observed in microstructure.

A) Graphitization:

Prolonged exposure of plain carbon steel to around 400°C temperature decomposes the pearlite into
iron and graphite and thereby reduces the mechanical strength. It can also severely embrittle the
steel when microstructure contains graphite particles or nodules. This is time and temperature
related phenomena at the lower temperature, it takes long time for graphitization.

B) Degradation of Pearlite:

Prolonged high temperature exposure on carbon and low- alloy steel material, where pearlite
colonies are broken and get converted in to spheroids. However addition of chromium prevents
spherodization. Pearlite degradation level can also provide guidelines for preventive maintenance.
Pearlite phase imparts strength to the steel and its degradation is a matter of concern.
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
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C) Creep Damage:

Time related temperature dependent deformation under stress is known as creep. The degradation is
stage wise and it can show the initiation in the microstructure as creep voids, orientation of creep
voids and micro-cracks in the microstructure. This study provides useful information of material
degradation which can be quantified to evaluate remaining life of the component. The creep stages
are depicted in following figure.

D) Thermal Fatigue:

When component is subjected to cyclic temperature, thermal expansion causes thermal stresses,
which may eventually initiate and propagate the fatigue cracks. The damage is observed when
temperature fluctuations are expected.

E) High Temperature Oxidation:

Oxidation occurs from the grain boundary and penetrates inside. The thickening of grain boundary in
plain carbon steel material can be observed with etching response.
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
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F) Decarburization:

Microstructure can identify the absence of pearlite phase normally observed in steel microstructure.
Decarburization reduces the strength of material. Fuel gases / wet steam leads to decarburization.
Reducing nature of atmosphere in the furnace causes decarburization of steel surfaces. In-situ
Metallography approach would help to find out presence of decarburizing tendency in the
microstructure of components and provides feedback for improvement in the furnace atmosphere.

G) Grain Coarsening:

Prolonged high temperature exposure will coarsen the grain and decreases the strength of material.

All above damage mechanisms are possible to identify with the help of In-situ Metallography and
compare with normal microstructure or base line microstructure condition mentioned in test
certificate or either with reference data. With expertise and experience in microstructure
interpretation, corrective action can be carried out.
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page 10 of 146

5. Various Techniques / Methodology For Residual Life Assessment

Of Boiler
1. CALCULATION METHODS:

The analytical methods are aimed at estimating residual life based on operating history, component’s
geometry and material properties. Because of inaccuracies and uncertainties in measurement and
assessment of these parameters, this technique may lead to inaccuracies in residual life prediction.

2. EXTRAPOLATION OF STATISTICS OF PAST FAILURES:

For components such as boiler tubes, which are numerous in a given plant, which perform identical
functions, and whose failure is not critical to plant safety, a history of past failures rate can provide a
useful index of potential future failure rates. In this methodology only components with similar
composition, heat treatment, operating history and failure mechanism are populated; hence this
method is having limitation in its application.

3. BASED ON DIMENSIONAL MEASUREMENTS:

Some equipment such as bow micrometers can determine strain in pipe from dimensional
measurement in ambient condition with suitable high accuracy. An accuracy of 0.1 % can be achieved
with this method. Distortions measured through such equipments are used to determine
accumulated strain. The accumulated strain is then compared with the expected failure strain of the
material used. If measurements are done at frequent intervals, the creep rate of material can be
established and the remaining life can be estimated.

4. METALLOGRAPHIC METHODS:

Metallographic methods can correlate either cavitations evolution or changes in carbide spacing and
their spherodisation with creep life expenditure. It has been observed that in boiler, pipe cavitation is
the principal damage mechanism at the brittle zones and high stress regions. In other cases, carbide
coarsening and cavitations are better indicators of life consumption. This method is very expensive,
however very useful for condition assessment and residual life assessment study. In-situ
Metallography techniques are also used to take microstructures of the components at the site.
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
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5. METHODS BASED ON TEMPERATURE ESTIMATION:

One of the crucial parameter in estimation of creep life is the operating temperature. Due to load
fluctuations and steam side oxide scale growth during operation increases effective tube wall
temperature and changes microstructure. Systematic database and periodic monitoring of
microstructure would allow the estimation of operating tube wall temperature. It also reflects by way
of Hardness, microstructure and thickness of oxide scale towards steam side. By estimating internal
scales which is function of time and temperature and their current thickness values may be used to
estimate an “equivalent” thermal history for a given operating time. The estimated temperature than
can be used in conjunction with standard stress rupture data to estimate the remaining life.

6. POST SERVICE CREEP RUPTURE TESTS:

A very common way of estimating remaining life under creep conditions is the use of stress rupture
tests on service exposed material. In the case of tubes and thin components, this method provides a
direct estimate of the expended creep life. In the case of thick section components, estimate of
expended and remaining life pertains only to crack initiation. These estimates must be coupled with
crack growth analysis to determine the overall remaining life.

7. FRACTURE MECHANICS APPROACH:

It is also called as Ct parameter Approach. Components, which are subjected to stress and
temperature gradients (typical of headers and pipes) generally, do not fail by creep rupture. It is more
likely that at the end of the predicted life, a crack will initiate at the critical location, propagate and
eventually cause failure. The difference between the actual life and the predicted from creep rupture
data would thus correspond to crack propagation life. A similar situation exists when failure
originates at pre-existing defects. In such case, the life assessment procedure should involve a
fracture mechanics approach. A value of critical size is established and the crack growth analysis is
performed to determine the remaining life. The remaining life is the time required for an initial crack
detected during inspection to grow to theoretical critical size.

8. INTEGRATED APPROACH:

Apart from the different techniques, an overall life assessment approach is applied which includes
visual inspection, NDE, replica and material test. TCR Arabia has adopted integrated approach.
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
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THE GENERAL PROCEDURE FOR PERFORMING RLA

1. Past history/ data collection and study

Study of O&M manual and water chemistry, to identify and understand design requirements,
operating conditions. Past failure history and operational deviations helps to decide the location for
detailed study.

2. Analysis of operational / maintenance / overhaul records

To know current status of the unit and components those are undergoing degradation.

3. Visual observation

To study macroscopic damage such as erosion, corrosion, oxidation, bending, misalignment

4. Dimensional measurement

To determine approximate swelling due to Creep, Erosion, Corrosion etc.

5. Condition assessment

It involves Non-destructive Inspection of critical and non-critical components like LPI, MPI, UI,
Boroscopy etc. to find out whether defects are present at the surface, subsurface or deep within the
components.

6. In-situ Metallography (replica technique) and hardness measurement

Technique used to find out in-service degradation of microstructure in terms of creep, thermal shock
and operational abuses. The advance stage of creep life can be judged in order to provide early
warning of failure. This information is useful to retire the component.

7. Analysis of results and residual life assessment

To determine the present condition of the boiler and remaining creep life of the critical pressure
parts of the boiler based on microstructure analysis under the given set of operating conditions.

8. Conclusions and recommendations for life extensions

Recommendations are made based on different analysis whether to continue, repair, modify or
replace the components. Future inspection intervals for condition assessment for monitoring the
damage are also recommended.
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page 13 of 146

6. INTRODUCTION TO NON-DESTRUCTIVE TESTS

MAGNETIC PARTICLE INSPECTION

This test is used to detect surface and subsurface defects in the ferromagnetic materials. In this test,
a single phase AC/HWDC/DC current is made to flow through a horseshoe shaped electromagnet.
This induces longitudinal magnetizing flux in the component.

When a ferromagnetic material is magnetized, magnetic lines of force start travelling through the
material forming poles. If any surface and sub-surface discontinuity is present in an area of magnetic
field, it causes a leakage in the magnetic field. This means that, magnetic lines of force get deflected
creating leakage field. If fine particles of magnetic material are applied on the surface, upon
application of magnetic field, magnetic particles get attracted in the area where there is leakage of
field. By studying the pattern of these attracted particles; location, shape, size and nature of
discontinuity can be analyzed. In the absence of discontinuity the magnetic powder remains in the
form of randomly oriented dispersion.

Magnetic powder is ferromagnetic material. It is a combination of rounded and elongated particles.

Rounded particles are for better flow-ability in discontinuity and elongated particles are for better
vision of discontinuity. Fluorescent magnetic particles are used for better resolution and sensitivity.
The magnetic powder should be sprayed after magnetic field is applied.

ULTRASONIC INSPECTION
This technique is used to detect internal defects in material. Defects occurred during fabrication,
operation and maintenance can be detected by this technique.

This method is known as pulse echo contact method. The sound waves are transmitted into the
component of the order of 2MHz t0 10 MHz depending upon the application. If the defect is present
in the material, reflected sound waves from defect and its respective indications are analyzed based
on the DAC curves on the CRT screen of Ultrasonic Flaw Detector.

The outer surface of the material should to be cleaned properly to achieve smooth surface so that
ultrasonic probe can have better contact and movement over the surface of the component to be
examined.
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
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Selection of probe depends on the material specification, processing, thickness etc. and subsequently
calibration of the equipment is done.

After selecting the appropriate range for test, grease/oil is applied over the surface as a couplant to
avoid air gap and to provide good contact between probe and the surface.

Probe is moved over the surface of the component to be examined. The indications from any defect
will appear on the CRT screen as in the form of loss of back wall echo or a separate echo between the
surface and backwall echo or both. It is then processed to define the type, size and severity of defect
by necessary calculations.

HARDNESS MEASUREMENT
Hardness measurement is carried out to study the loss of strength due to creep and thermal
softening.

The equipment is calibrated by standard hardness blocks before the test. The change in velocity of
indentor having steel ball has been directly converted to the hardness reading by a microprocessor.
Hardness readings can thus be obtained directly from the machine in BHN.

IN-SITU METALLOGRAPHY (REPLICA)

The microstructure analysis gives an indication of metallurgical damages including creep damage. The
samples are polished with different grit size papers to get mirror image with the help of portable
grinding and polishing machine. Once the surface is prepared, it is etched and replicas are obtained
from the surface. These replicas are studied under the microscope and microstructure analysis is
carried out to determine creep damage.

Equipment and consumable: Insipol - 2000 make electropolishing and etching unit with transparent
replicas.

Process technique:

The microstructure preparation is time consuming and requires experienced and skilful personnel
among all the non-destructive methods employed to estimate the remaining life of boiler
components. However, this technique is important since it gives a very good indication of the
structural degradation of steel and thus provides early warning for component replacement.
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
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In this method, the mirror like surface is obtained by the means of careful grinding followed by
buffing of the surface. For this purpose, grinding and buffing wheels are used.

The sequence of grinding is as follows :

Rough grinding with portable hand electric die grinder with emery of 60 grits size.

Grinding with portable grinder and polisher with 80, 120, 220, 320, 500, 1000-grit size emery.
Polishing with diamond paste of 3 micron and 1 micron respectively with two different cloths

After that final buff is given with the help of a diamond paste. The surface is thoroughly cleaned with
swabbing with acetone to remove any adherent dirt or foreign particles.

It is cleaned with the pure cotton once again; etching is carried out with 2% Nital for around 1-5
minutes depending on the material and etching response.

After etching, immediately acetone swabbing is done for uniform drying.

Once etching is complete, replica is made with replica liquid on one side and then applied over the
surface. It is pressed with the thumb to apply adequate pressure.

Replica is allowed to stick on the surface. If it does not come out at its own, it is removed after 10-15
minutes.

After that replica is carefully preserved between two slides

The analysis is done according to internationally accepted microstructure degradation criteria as

follows:

Microstructure Degradation Levels

Creep Degradation Levels (Refer Creep Curve)

 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
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CREEP SEVERITY LEVEL MICROSTRUCTURE OBSERVATION ACTION RECOMMENDED

Formation of distinct isolated None until next major scheduled
A
cavities. maintenance outage.
Formation of linked cavities to
B Replica Test after three years
form micro cracks

C Formation of micro cracks Replica Test after one year

Linking of micro cracks to form a

D Immediate Repair/Replace
macro crack
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
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7. Key Observations & Findings

7.1 Main Steam Line
One Main steam pipe line carries the final steam to turbine. There are several joints on this line. This
entire pipe line is made from ASTM P
219.1x18.26 mm.
UT of butt joints was carried out. No significant discontinuity observed.
WFMPI for butt joints was carried out at accessible locations. No significant discontinuity observed.
Replica was performed on Parent metal and Weld /HAZ region side for assessment of microstructure
damage. Microstructure shows decomposition of bainite/pearlite into ferrite and carbides, but still
original traces of the ferrite and Bainite are present. At replica location 1, 2,3,5,8 and12 places
microstructure displayed Initial level of oriented creep cavities. At rest of the locations microstructure
displayed initial level of isolated creep cavities.
The hardness values are in range of 109-147 BHN in parent metal, 139 – 172 BHN in HAZ and 134 -
213 BHN in weld region. It is found in acceptable range for further operation. The hardness testing
on base metal and weld did not reveal any abnormalities.
Thickness measurement showed acceptable values of available thickness.

7.2 HTSH Outlet Header

These High Temperature Superheater inlet and outlet Headers are made of ASTM A 335 Grade P 12
and P 22 respectively. The dimension of inlet headers are dia. 328 x 32 mm and outlet headers are
dia. 425 x 55 mm
WFMPI for butt joints was carried out at accessible areas. No recordable indication was observed.
Replica was performed on Parent metal and Weld /HAZ region side for assessment of microstructure
damage. Microstructure shows decomposition of bainite/pearlite into ferrite and carbides, but still
original traces of the ferrite and Bainite are present. At some places microstructure displayed Initial
level of isolated creep cavities.
The hardness values are in range of 129-187 BHN in parent metal, 178 – 187 BHN in HAZ and 166-177
BHN in weld region. It is found in acceptable range for further operation. The hardness testing on
base metal and weld did not reveal any abnormalities.
7.3 LTSH Outlet Header
WFMPI for butt joints was carried out at accessible areas. No recordable indication was observed.
Replica was performed on Parent metal and Weld /HAZ region side for assessment of microstructure
damage. Microstructure shows decomposition of bainite/pearlite into ferrite and carbides, but still
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
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original traces of the ferrite and Bainite are present. At some places microstructure displayed Initial
level of isolated creep cavities.
The hardness values are in range of 123-129 BHN in parent metal, 140 – 147 BHN in HAZ and 169-183
BHN in weld region. It is found in acceptable range for further operation. The hardness testing on
base metal and weld did not reveal any abnormalities.

7.4 HT Super heater Tubes

These tubes are in the convective zone of the boiler and carry the super saturated steam at 513°C i.e.
the main steam. The material of these tubes is SA 213 Grade T-11 and T-22.
All tubes displayed initial level of creep degradation in terms of spherodization of pearlite and
presence of initial level of oriented creep cavities.
Laboratory tests like tensile test, hardness test, microstructure analysis at cross sections confirms
that tubes are as per required specifications.
Coil 70(F-7), tube # PO 3, – ASTM A213 grade T11
Coil 50 (F-17), tube#P13 – ASTM A 213 grade T22
Coil 20, (F-13) tube#PO 9 – ASTM A 213 grade T22
Deposit on ID side was collected from the above tubes. The scale thickness at ID is in the range of
150-300 microns. EDS analysis indicates the presence of Copper and Nickel, which indicates that
there may be leakage in the condenser.
Microstructure at cross sections reveals micro cracks at OD and ID up to depth of 1 grain which does
not cause immediate concern.

7.5 LT Super heater Tubes

In situ metallography revealed initial level of degradation in LT super heater tubes.
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page 19 of 146

8. Analysis of Findings and Judgment on Remaining Life Assessment

Main steam line
Thickness measurement indicated no significant reduction in thickness value. Microstructure under
optical as well as SEM indicates initial level of degradation in terms of initial level of oriented creep cavities at
replica locations 1,2,3,5,8, 12 and initial level of isolated creep cavities at other replica locations, thus
indicating good remaining life of these components from microstructure degradation point of view.

LTSH header
WFMPI was carried out at weld joints, where no recordable indication was observed. No significant
damage in terms of degradation observed. LTSH outlet header is in good condition and can continue
for further operation.
HTSH header
WFMPI was carried out at weld joints, where no recordable indication was observed. Microstructure
under optical as well as SEM indicates initial level of degradation in terms of initial level of isolated
creep cavities, thus indicating good remaining life of these components from microstructure
degradation point of view. HTSH outlet header is in good condition and can continue for further
operation.
LTSH tubes
Thickness measurement reveals a thickness loss of maximum 4.5% which is acceptable .Initial level of
degradation observed in LTSH tubes.
HTSH tubes
All tubes show initial level of creep degradations in terms of spherodization of pearlite. Laboratory
testing confirms that tubes are as per required specifications. Microstructure of tubes shows micro
cracks up to depth of 1 grain which does not indicate immediate concern.
The scale thickness at ID is in the range of 150-300 microns; indicating the overall condition of tube
having higher internal scale. EDS analysis of oxide scale at ID indicates the presence of Copper and
Nickel, which indicates that there may be leakage in the condenser.
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page 20 of 146

9. Recommendations

Microstructure analysis and creep life evaluation suggests that Main steam Pipe Line can be
continued in the service for further 44000 hours provided it is operated under the O&M guidelines
given by the original equipment manufacturer. However, it is recommended to re-evaluate the life
after 44000 running hours with thorough RLA assessment. It is recommended to monitor
microstructure after 26000 running hours (3yr).

LTSH and HTSH headers can be continued in the service for further 88000 hours provided it is
operated under the O&M guidelines given by the original equipment manufacturer. It is
recommended to carry out re-inspection after 44000 hours of operation i.e. 5 yrs.

LTSH tubes show initial level of degradation however; it can be continued in the service for 44000
hours i.e. 5yrs, provided it is operated under the O&M guidelines given by the original equipment
manufacturer.

HTSH tubes show initial level of creep degradation in terms of spherodization of pearlite. Laboratory
testing suggests, tubes confirm to required specification.

It did not show presence of any creep cavities at the grain boundaries under destructive analysis.
There are presence of micro pitting and inter-granular cracks at ID and OD but they are about one
grain deep which does not cause of immediate concern. EDS analysis of oxide scale at ID indicates the
presence of Copper and Nickel, which suggests that there may be leakage in the condenser.

It is suggested to carry out inspection of these HTSH tubes after 26000 running hours i.e. after three
years.
 Report No.:TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
Date: 01.02.2010
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Report on RLA of Boiler Components, Phase I, Boiler # 5 Page 21 of 146

LABORATORY TESTING OF

HIGH TEMPERATURE SUPERHEATER TUBES

INTRODUCTION

As a part of RLA study of super heater tubes, three tubes were sent to Laboratory for nondestructive

tests like Visual, Dimension inspection, Magnetic Particle Inspection and destructive tests like, Tensile

test, Hardness test, Microstructure examination with optical as well as Scanning Electron Microscopy

at cross section; Thickness, Density and Chemical composition of internal scale deposit. Based on the

test results and internal oxide scale measurement the safe re-assessment period of tube operation is

judged keeping in view of microstructure degradations.

Details of tube

Tube A
Location Coil # 70, Tube no. P03, F-7
Material A 213 grade T11, 50.8mm OD x 4.0mm thick
Quantity 1Pc. 1000mm long
Tube B
Location Coil # 50, Tube no. P13, F-17
Material A 213 grade T22, 50.8mm OD x 7.2mm thick
Quantity 1Pc. 1000mm long
Tube C
Location Coil # 20, Tube no. P09, F-13
Material A 213 grade T22, 50.8mm OD x 5.0 mm thick
Quantity 1Pc. 1000mm long
 Report No.:TCR/002/10/RLA
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Date: 01.02.2010
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Report on RLA of Boiler Components, Phase I, Boiler # 5 Page 22 of 146

Sample ID - A - Coil # 70, Tube no. P03, F-7

(A.1) EDS ANALYSIS

EDS Analysis conducted at ID Scale of the tube.
Table: 1 shows the result of EDS analysis.
Table: 1 Result of EDS Analysis of internal scale

Elements % age
O 22.14
Mg 1.04
Fe 58.93
Ni 2.32
Cu 15.57

(A.2) INTERNAL SCALE WEIGHT MEASUREMENT

Table: 2 Results of Scale Weight Analysis
Tube Length in mm 500
Weight of Scale in mg 127.9
Calculated surface area mm2 60590
Scale weight in mg/mm2 0.00211
 Report No.:TCR/002/10/RLA
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Date: 01.02.2010
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(A.3) MICROSTRUCTURE EXAMINATION

A.3.1 Optical metallography
Microstructure examination was carried out at Transverse Cross-section.

TRANSVERSE CROSS-SECTION - TUBE - A2

Plate: 1
Plate: 1 shows specimen in as mounted condition.

Plate:2-TS at OD (100X) Plate:3-TS at Core (100X) Plate:4-TS at ID (100X)

Plate:5-TS at OD (400X) Plate:6-TS at Core (400X) Plate:7-TS at ID (400X)

 Report No.:TCR/002/10/RLA
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Date: 01.02.2010
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Plate: 2, 3 & 4 microstructure shows fine grained essentially ferrite structure with carbides at the grain boundaries
and within the grains. At OD coarse ferrite grains are observed with micro cracks up to depth of 1 grain depth.
Corrosion and micro cracks are observed at Internal surface. Microstructure shows initial level of pearlite
degradations.
Plate: 5, 6 & 7 higher magnification photos at OD, core and ID, microstructure indicates initial stage of oxidation
cracks at the grain deep level, indicates initial level of grain boundary cracking up to one grain deep level.

Plate: 8 Core (1000X) Plate: 9 Core (2000X)

Plate: 8 & 9 shows fine grained essentially ferrite structure with carbides at the grain boundaries and within the
grains. This indicates spheroidization of pearlite/bainite.

A.3.2 SEM Observations

Plate: 10-LS at OD (1000X) Plate: 11-LS at Core (1000X) Plate: 12-LS at ID (1000X)
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Plate: 10, 11 & 12 are SEM images showing micro cracks at ID and OD that are in the infant conditions. No
indication of any grain boundary creep cavities is observed.

Plate:13 Core (2000X) Plate:14 Core (3500X)

Plate: 13 & 14 are SEM images at higher magnification, No significant creep damage is observed at the grain
boundaries. It shows in situ spheroidization of pearlite/bainite in the microstructure. The microstructure shows
second stage of creep damage.

(A.4) OXIDE SCALE MEASUREMENT

Plate: 15 – OD 200X Plate: 16 – ID 200X

 Report No.:TCR/002/10/RLA
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Oxide scale thickness at OD Oxide scale thickness at ID

Frames
Measurement (Micron) Measurement (Micron)
1 60.1 183.9
2 65.8 200.0
3 58.9 188.6
4 60.5 189.4
5 57.8 194.4
Average of 5 frames 60.62 191.26

(A.5) TENSILE TEST

Tensile and hardness test was carried out on the test piece drawn from the tube specimen. (Table: 3).
Table: 3 Result of Tensile Test
Measured Required Values (min)
Thickness (mm) 4.45 -
Width (mm) 18.98 -
2
Area (mm ) 84.46 -
Gauge Length (mm) 50.00 -
Final Length (mm) 66.72 -
Yield Load (N) 37500 -
Ultimate Load (N) 42920 -
2
Yield Stress (N/mm ) 444 205
2
U. T. S. (N/mm ) 508 415
% Elongation 33.44 23
Fracture W. G. L. -
(A.6) HARDNESS TEST
Table: 4 Result of Hardness Test
Location ID. Hardness in “HBW” at 187.5 kg load. Required values
Core 153, 153, 153 163 HBW max

The above results of tensile and hardness test confirms to A231 grade T11 specifications
 Report No.:TCR/002/10/RLA
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(A.7) Visual Inspection

A 1 2 3

C B

Table : 5 Ultrasonic Thickness Measurement

Measured Thickness
Location Nominal Thk
A % Change B % Change C % Change

1 4.0 4.2 - 4.0 - 4.2 -

2 4.0 4.2 - 4.1 - 4.0 -

3 4.0 4.1 - 4.3 - 4.1 -

Outer Surface Visual Inspection

Remarks: At places, scaling is observed on outer surface.

 Report No.:TCR/002/10/RLA
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Date: 01.02.2010
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Sample ID – B: Coil # 50, Tube no. P13, F-17

(B.1) EDS ANALYSIS

EDS Analysis conducted on Inner Surface.

Table: 1 shows the result of EDS analysis.

Table: 1 Result of EDS Analysis

Elements % age

O 19.67

Mg 0.55

Ca 0.57

Fe 76.03
Ni 3.18
 Report No.:TCR/002/10/RLA
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(B.2) INTERNAL SCALE WEIGHT MEASUREMENT

Table: 2 Results of Scale Weight Analysis
Tube Length in mm 496
Weight of Scale in mg 148.6
Calculated surface area mm2 56221
Scale weight in mg/mm2 0.00264
(B.3) MICROSTRUCTURE EXAMINATION
B.3.1 Optical metallography
Microstructure examination was carried out at. Transverse Cross-section.

Initially, the examination was done in ‘As polished’ condition and then in ‘Etched’ condition.

TRANSVERSE CROSS-SECTION –TUBE- B-2

Plate: 1
Plate: 1 shows specimen in as mounted condition.

Plate:2-TS at OD (100X) Plate:3-TS at Core (100X) Plate:4-TS at ID (100X)

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Plate:5-TS at OD (400X) Plate:6-TS at Core (400X) Plate:7-TS at ID (400X)

Plate: 2, 3 & 4 are the etched views at OD, Core and ID respectively in the transverse direction. Showing fine
grained ferrite and pearlite/bainite structure.

Plate: 5, 6 & 7 Enlarge view of microstructure shows ferrite and spheroidial pearlite/bainite structure. On
outer surface presence of oxide scale is observed along with grain attack deep.

Plate:8 Core (1000X) Plate:9 Core (2000X)

Plate: 8 and 9 show presence of carbides at the grain boundaries and in situ spheroidization of
pearlite/bainite in the microstructure.
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B.3.2 SEM observation

Plate:10-LS at OD (2000X) Plate:11-LS at Core (1000X) Plate:12-LS at ID (1000X)

Plate: 10, 11 & 12 show SEM picture of microstructure showing ferrite grains with carbides at grain
boundaries and within the grains. At ID minor corrosion damage is observed.

Plate:13 Core (2000X) Plate:14 Core (3500X)

Plate: 13 and 14 microstructure shows spheroidized carbides at the grain boundaries and within the grains.
Microstructure is free from any creep indication of having any grain boundary cavitation damage.
 Report No.:TCR/002/10/RLA
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Date: 01.02.2010
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(B.4) OXIDE SCALE MEASUREMENT OF TUBE – B

Plate: 1 – OD 100X Plate: 1– ID 100X

Oxide scale thickness at OD Oxide scale thickness at ID
Frames
Measurement (Micron) Measurement (Micron)
1 165.7 191.4
2 185.7 157.2
3 231.4 75.2
4 197.2 183.0
5 234.3 185.7
Average of 5 frames 202.86 158.5

(B.5) TENSILE TEST

Tensile test was carried out on the test piece drawn from the tube specimen. The results are shown in
table: 3. They are satisfactory.
Table: 3 Result of Tensile Test
Measured Required Values (min)
Thickness (mm) 6.67 -
Width (mm) 19.14 -
2
Area (mm ) 127.66 -
Gauge Length (mm) 50.00 -
Final Length (mm) 68.86 -
Yield Load (N) 44000 -
Ultimate Load (N) 59600 -
2
Yield Stress (N/mm ) 345 205
2
U. T. S. (N/mm ) 467 415
% Elongation 37.22 27
Fracture W. G. L. -
 TCR ARABIA COMPANY LIMITED Report No.:TCR/002/10/RLA

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Report on RLA of Boiler Components, Phase I, Boiler # 5 Page 33 of 146
(B.6) HARDNESS TEST
General hardness was measured at different locations and results are tabulated in table: 4.
Table: 4 Result of Hardness Test
Location ID. Hardness in “HBW” at 187.5 kg load. Required values
Core 138, 138, 138 163 HBW max

(B.7) Visual Inspection

A 1 2 3

C B

Table : 5 Ultrasonic Thickness Measurement

Nominal Measured Thickness
Location
Thk A % Change B % Change C % Change
1 7.2 7.1 - 7.0 - 7.1 -
2 7.2 7.2 - 7.1 - 7.2 -
3 7.2 7.3 - 7.1 - 6.9 -

Outer Surface Visual Inspection

Remarks: At places, scaling is observed on outer surface.

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Sample ID - C : Coil # 20, Tube no. P09, F-13

(C.1) EDS ANALYSIS

EDS Analysis conducted on Inner Surface.
Table: 1 shows the result of EDS analysis.
Table: 1 Result of EDS Analysis

Elements % age

O 25.26
Si 0.48
Fe 72.71

Ni 1.55

(C.2) INTERNAL SCALE WEIGHT MEASUREMENT

Table: 2 Results of Scale Weight Analysis
Tube Length in mm 493
Weight of Scale in mg 236.9
Calculated surface area mm2 56916
2
Scale weight in mg/mm 0.00416
 Report No.:TCR/002/10/RLA
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Date: 01.02.2010
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(C.3) MICROSTRUCTURE EXAMINATION

C.3.1 Optical metallography
Microstructure examination was carried out at Transverse Cross-section.

Initially, the examination was done in ‘As polished’ condition and then in ‘Etched’ condition.

TRANSVERSE CROSS-SECTION –TUBE- C-2

Plate: 1
Plate: 1 shows specimen in as mounted condition

Plate:2-TS at OD (100X) Plate:3-TS at Core (100X) Plate:4-TS at ID (100X)

Plate:5-TS at OD (400X) Plate:6-TS at Core (400X) Plate:7-TS at ID (400X)

 Report No.:TCR/002/10/RLA
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Date: 01.02.2010
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Plate: 2, 3 & 4 are the etched views at OD, Core and ID respectively in the transverse direction. Showing fine
grained ferrite and pearlite/bainite structure.
Plate: 5, 6 & 7 Enlarge view of microstructure shows ferrite and spheroidal pearlite/bainite structure. On
outer surface presence of oxide scale is observed along with grain attack deep. Minor corrosion is
observed at the internal surface.

Plate: 8 Core (1000X) Plate: 9 Core (2000X)

Plate: 8 and 9 shows presence of carbides at the grain boundaries and in-situ spheroidization of
pearlite/bainite in the microstructure.

C.3.2 SEM observations

Plate: 10-LS at OD (1000X) Plate: 11-LS at Core (1000X) Plate: 12-LS at ID (1000X)
Plate: 10, 11 & 12 show SEM picture of microstructure showing ferrite grains with carbides at grain
boundaries and within the grains. At ID minor corrosion damage is observed.
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Plate:13 Core (2000X) Plate:14 Core (3500X)

Plate: 13 and 14 microstructure shows spheroidized carbides at the grain boundaries and within the
grains. Microstructure is free from any creep indication of having any grain boundary cavitation damage.

(C.4) OXIDE SCALE MEASUREMENT OF TUBE – C

Plate: 1 – OD 100X Plate: 1– ID 100X

Oxide scale thickness at OD Oxide scale thickness at ID
Frames
Measurement (Micron) Measurement (Micron)
1 257.1 282.9
2 251.4 277.5
3 194.3 277.7
4 214.3 270.7
5 268.6 328.6
Average of 5 frames 237.14 287.48
 TCR ARABIA COMPANY LIMITED Report No.:TCR/002/10/RLA

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Report on RLA of Boiler Components, Phase I, Boiler # 5 Page 38 of 146
(C.5) TENSILE TEST
Tensile test was carried out on the test piece drawn from the tube specimen. The results are shown
in table: 3. They are satisfactory.
Table: 3 Result of Tensile Test
Measured Required Values (min)
Thickness (mm) 5.71 -
Width (mm) 19.00 -
2
Area (mm ) 108.49 -
Gauge Length (mm) 50.00 -
Final Length (mm) 66.16 -
Yield Load (N) 33000 -
Ultimate Load (N) 51960 -
2
Yield Stress (N/mm ) 304 205
2
U. T. S. (N/mm ) 479 415
% Elongation 32.32 24
Fracture W. G. L. -
(C.6) HARDNESS TEST
General hardness was measured at different locations and results are tabulated in table:4
Table: 4 Result of Hardness Test
Location ID. Hardness in “HBW” at 187.5 kg load. Required values
Core 137, 137, 137 163 HBW max
(B.7) Visual Inspection
A 1 2 3

C B
Table : 5 Ultrasonic Thickness Measurement
Nominal Measured Thickness
Location
Thk A % Change B % Change C % Change
1 5.0 5.7 - 5.7 - 5.3 -
2 5.0 5.5 - 5.5 - 5.2 -
3 5.0 5.2 - 5.3 - 5.3 -
Outer Surface Visual Inspection

Remarks: At places, scaling is observed on outer surface.

 TCR ARABIA COMPANY LIMITED Report No.:TCR/002/10/RLA

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INFERENCES

All three tubes confirms to the required specification for strength and ductility properties at room

temperature. No significant degradation with respect to creep damage is observed under optical as

well as SEM examination of metallographic sample prepared on cross section. It shows initial level of

microstructure degradations in form of spheroidization of pearlite/bainite. Microstructure at OD

shows relatively coarse grains and seems to be present from the manufacture stage and micro cracks

up to depth of 1 grain both at OD as well as ID. The infant stage of grain boundary damage from the

OD is not very harmful however grain boundary cracking at the ID showed is matter of concerned

and suggests the chemical attack from ID. The depth of attack is not significant for immediate

concerns.

The boilers seems to be in idle conditions for varying periods ranging from 5 to 15 days with the

steam drum filled with water and vent valve of the drum kept open. During this time there are

chances of oxygen getting diffused into the boiler water and making it corrosive. The boiler system

needs to be preserved properly to prevent any ingress of oxygen. It seems that idle boilers were fired

with water already hold up in system which may be saturated with oxygen due to lack of

preservation. This would aggravate corrosion at vulnerable areas within pits already formed or in

places where scales are formed or copper is deposited.

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EDS analysis of internal scale shows presence of copper and Nickel. The presence of copper and

Nickel can come from the condenser leakage and carryover of the scale from its leakage if the

condenser is made of cupronickel tubes. Copper in boiler tube is detrimental and cause corrosion in

boiler tubes. Once the protective magnetite scales are removed, the steel tube can corrode and the

rate of corrosion gets accelerated if noble elements like copper are present in an environment

of electrolytic / ionic condition of water. The plated out copper on the tube surface acts as a

galvanic couple with the steel tube.

Based on microstructure degradations it is inferred that tubes may be continued in the service and

should be monitored after 45000 running hours. Root cause investigation of clit failures and

distortion may be done find out the reasons of failure and thereby eliminating it from the system.
 IN SITU METALLOGRAPHY, HARDNESS AND SEM REPORT

Metallography performed at SALINE WATER CONVERSION CORPORATION, JUBAIL

Reference 3210/4580

Portable Optical Microscope, Portable Grinder, Replica Kit,

Instrument used
Portable Hardness Tester

Plant Name PHASE-1 Boiler Unit # 5

In-situ Metallography & Hardness Work On main stream

Equipment
line
A217 WC6, A335 P11, A335 P12, A335 P22, A213 T11,
Material of construction
A213 T22, A213 T11

Date of testing 12.10.2009 to 26.10.2009

Total No of Metallography locations 34 Locations

Metallography replica prepared by Gaurang Gore

Date of report 14.11.2009

Interpretation and analysis

TCR Engineering Services, India
performed at
Metallography replica interpretation
Mr. Paresh U. Haribhakti, (Director)
done by

Total Pages 69
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 41 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL

Details of Replica Sketch not to the scale

Interpretation is done in absence of operating parameters of the component.

 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 42 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – Y1-Joint No.R7 Pipe side W/HAZ @ 12 O’clock Position

Location_1

Sketch not to the scale Plate: 1-Weld/HAZ (100X) Plate: 2-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
PM-
carbides in dendritic form. Where as at HAZ microstructure Initial level of
130, 127, 129
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 1 Weld-
1. A335 P11 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) 140, 138, 147
Initial stage of degradations in terms of carbide formation gold sputtering are
HAZ-
at bainite regions are observed however prior bainite kept at next page.
157, 143, 146
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 43 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- Y1-Joint No.R7 Pipe side W/HAZ @ 12 O’clock Position

Plate: 3-Weld/HAZ 1000X Plate: 4-HAZ 3500X

SR.NO. SEM Observation after gold sputtering of replica

1 Initial level of oriented creep cavities are observed at HAZ Monitor after 3 years of service.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 44 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – Y1-Joint No.R7 Forging side W/HAZ @ 12 O’clock Position

Location_2

Sketch not to the scale Plate: 5-Weld/HAZ (100X) Plate: 6-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
PM-
carbides in dendritic form. Where as at HAZ microstructure Initial level of
109, 111, 116
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 2 Weld-
2. A217 WC6 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) 146, 145, 139
Initial stage of degradations in terms of carbide formation gold sputtering are
HAZ-
at bainite regions are observed however prior bainite kept at next page.
148, 150, 152
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 45 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- Y1-Joint No.R7 Forging side W/HAZ @ 12 O’clock Position

Plate: 7-Weld/HAZ 1000X Plate: 8-HAZ 3500X

SR.NO. SEM Observation after gold sputtering of replica

2 Initial level of oriented creep cavities are observed at HAZ Monitor after 3 years of service.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 46 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – Y1-Joint No.R8 Pipe side crack W/HAZ @ 12 O’clock Position

Location_3

Sketch not to the scale Plate: 9-Weld/HAZ (100X) Plate: 10-HAZ (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
PM-
carbides in dendritic form. Where as at HAZ microstructure Initial level of
114, 117, 116
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 3 Weld-
3. A335 P11 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) 144, 145, 150
Initial stage of degradations in terms of carbide formation gold sputtering are
HAZ-
at bainite regions are observed however prior bainite kept at next page.
154, 152, 149
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 47 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- Y1-Joint No.R8 Pipe side crack W/HAZ @ 12 O’clock Position

Plate: 11-Weld/HAZ 1000X Plate: 12 -HAZ 3500X

SR.NO. SEM Observation after gold sputtering of replica

3 Initial level of oriented creep cavities are observed at HAZ Monitor after 3 years of service.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 48 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – Y1-Joint No.R8 Forging side W/HAZ @ 12 O’clock Position

Location_4

Sketch not to the scale Plate: 13-Weld/HAZ (100X) Plate: 14-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
PM-
carbides in dendritic form. Where as at HAZ microstructure Initial level of
112, 114, 110
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 4 Weld-
4. A217 WC6 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) 141, 135, 139
Initial stage of degradations in terms of carbide formation gold sputtering are
HAZ-
at bainite regions are observed however prior bainite kept at next page.
150, 146, 147
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 49 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- Y1-Joint No.R8 Forging side W/HAZ @ 12 O’clock Position

Plate: 15-Weld/HAZ 1000X Plate: 16 -HAZ 3500X

SR.NO. SEM Observation after gold sputtering of replica

No significant presence of creep cavities observed at the grain

4 Monitor after 5 years of service.
boundaries.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 50 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – Joint No.R1 Elbow side W/HAZ @ 12 O’clock Position

Location_5

Sketch not to the scale Plate: 17-Weld/HAZ (100X) Plate: 18-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
PM-
carbides in dendritic form. Where as at HAZ microstructure Initial level of
134, 134, 129
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 5 Weld-
5. A335 P11 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) 162, 165, 170
Initial stage of degradations in terms of carbide formation gold sputtering are
HAZ-
at bainite regions are observed however prior bainite kept at next page.
157, 154, 158
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 51 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- Joint No.R1 Elbow side W/HAZ @ 12 O’clock Position

Plate: 19-PM 1000X Plate: 20 -HAZ 3500X

SR.NO. SEM Observation after gold sputtering of replica

5 Initial level of oriented creep cavities are observed at HAZ Monitor after 3 years of service.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 52 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – Joint No.R1 Forging side W/HAZ @ 12 O’clock Position

Location_6

Sketch not to the scale Plate: 21-Weld/HAZ (100X) Plate: 22-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN

Initial level of
Microstructure at weld metal shows ferrite /bainite and PM-
degradation. SEM
Location: 6 carbides in dendritic form. Where as at HAZ microstructure 139 137, 131
6. A217 WC6 2% Nital observations after
(Weald/HAZ/PM) shows fine- and coarse tempered bainite structure. Weld-
gold sputtering are
Parent metal shows coarse tempered bainite structure. 162, 166, 170
kept at next page.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 53 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- Joint No.R1 Forging side W/HAZ @ 12 O’clock Position

Plate: 23-Weld/HAZ 2000X Plate: 24 -HAZ 2000X

SR.NO. SEM Observation after gold sputtering of replica

6 Isolated creep cavities are observed at HAZ Monitor after 5 years of service.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 54 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – T2 Joint No.R6 Pipe side W/HAZ @ 9 O’clock Position

Location_7

Sketch not to the scale Plate: 25-Weld/HAZ (100X) Plate: 26-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
PM-
carbides in dendritic form. Where as at HAZ microstructure Initial level of
121, 128, 132
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 7 Weld-
7. A335 P11 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) 176, 180, 178
Initial stage of degradations in terms of carbide formation gold sputtering are
HAZ-
at bainite regions are observed however prior bainite kept at next page.
150, 147, 140
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 55 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- T2 Joint No.R6 Pipe side W/HAZ @ 9 O’clock Position

Plate: 27- Weld/HAZ 1000X Plate: 28 -HAZ 2000X

SR.NO. SEM Observation after gold sputtering of replica

7 Isolated creep cavities are observed at HAZ Monitor after 5 years of service.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 56 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – T2 Joint No.R6 Forging side W/HAZ @ 9 O’clock Position

Location_8

Sketch not to the scale Plate: 29-Weld/HAZ (100X) Plate: 30-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
carbides in dendritic form. Where as at HAZ microstructure Initial level of
PM-
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 8 118, 120, 125
8. A217 WC6 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) Weld-
Initial stage of degradations in terms of carbide formation gold sputtering are
170, 184, 176
at bainite regions are observed however prior bainite kept at next page.
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 57 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- T2 Joint No.R6 Forging side W/HAZ @ 9 O’clock Position

Plate: 31- Weld/HAZ 1000X Plate: 32 -HAZ 3500X

SR.NO. SEM Observation after gold sputtering of replica

8 Initial level of oriented creep cavities are observed at HAZ Monitor after 3 years of service.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 58 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – Joint No.R10 Pipe side W/HAZ @ 12 O’clock Position

Location_9

Sketch not to the scale Plate: 33-Weld/HAZ (100X) Plate: 34-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
carbides in dendritic form. Where as at HAZ microstructure Initial level of
PM-
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 9 130, 126, 128
9. A335 P11 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) Weld-
Initial stage of degradations in terms of carbide formation gold sputtering are
150, 156, 145
at bainite regions are observed however prior bainite kept at next page.
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 59 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- Joint No.R10 Pipe side W/HAZ @ 12 O’clock Position

Plate: 35 - Weld/HAZ 1000X Plate: 36 - HAZ 2000X

SR.NO. SEM Observation after gold sputtering of replica

No significant presence of creep cavities observed at the grain

9 Monitor after 5 years of service.
boundaries.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 60 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – Joint No.R10 Elbow side W/HAZ @ 12 O’clock Position

Location_10

Sketch not to the scale Plate: 37-Weld/HAZ (100X) Plate: 38-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
PM-
carbides in dendritic form. Where as at HAZ microstructure Initial level of
128, 125, 131
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 9 Weld-
9. A335 P11 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) 172, 171, 176
Initial stage of degradations in terms of carbide formation gold sputtering are
HAZ-
at bainite regions are observed however prior bainite kept at next page.
145, 151, 148
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 61 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- Joint No.R10 Elbow side W/HAZ @ 12 O’clock Position

Plate: 39-Weld/HAZ 1000X Plate: 40 -HAZ 3500X

SR.NO. SEM Observation after gold sputtering of replica

10 Isolated creep cavities are observed at HAZ Monitor after 5 years of service.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 62 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – V2 Joint No.R3 Pipe side W/HAZ @ 6 O’clock Position

Location_11

Sketch not to the scale Plate: 41-Weld/HAZ (100X) Plate: 42-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
PM-
carbides in dendritic form. Where as at HAZ microstructure Initial level of
127, 135, 131
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 11 Weld-
11. A335 P11 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) 188, 189, 196
Initial stage of degradations in terms of carbide formation gold sputtering are
HAZ-
at bainite regions are observed however prior bainite kept at next page.
155, 161, 159
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 63 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- V2 Joint No.R3 Pipe side W/HAZ @ 6 O’clock Position

Plate: 43-Weld/HAZ 1000X Plate: 44 -HAZ 3500X

SR.NO. SEM Observation after gold sputtering of replica

No significant presence of creep cavities observed at the grain

11 Monitor after 5 years of service.
boundaries.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 64 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – V2 Joint No.R3 Forging side W/HAZ @ 6 O’clock Position

Location_12

Sketch not to the scale Plate: 45-Weld/HAZ (100X) Plate: 46-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
carbides in dendritic form. Where as at HAZ microstructure
shows fine-grained essentially ferritic structure with few Initial level of
PM-
pearlite/bainite. degradation. SEM
Location: 12 135, 134, 132
12. A217 WC6 2% Nital Parent metal shows fine-grained essentially ferritic observations after
(Weald/HAZ/PM) Weld-
structure with few pearlite/bainite. gold sputtering are
199, 190, 187
Initial stage of degradations in terms of carbide formation kept at next page.
at bainite regions are observed however prior bainite
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 65 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- V2 Joint No.R3 Forging side W/HAZ @ 6 O’clock Position

Plate: 47-Weld/HAZ 1000X Plate: 48 -HAZ 2000X

SR.NO. SEM Observation after gold sputtering of replica

12 Initial level of oriented creep cavities are observed at HAZ Monitor after 3 years of service.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 66 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – V1-Joint No.R2 Pipe side W/HAZ @ 12 O’clock Position

Location_13

Sketch not to the scale Plate: 49-Weld/HAZ (100X) Plate: 50-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN

Microstructure at weld metal shows ferrite /bainite and

PM-
carbides in dendritic form. Where as at HAZ microstructure Initial level of
124, 127, 126
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 13 Weld-
13. A335 P11 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) 169, 181, 178
Initial stage of degradations in terms of carbide formation gold sputtering are
HAZ-
at bainite regions are observed however prior bainite kept at next page.
160, 166, 165
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 67 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- V1-Joint No.R2 Pipe side W/HAZ @ 12 O’clock Position

Plate: 51--Weld/HAZ 1000X Plate: 52 -HAZ 3500X

SR.NO. SEM Observation after gold sputtering of replica

No significant presence of creep cavities observed at the grain

13 Monitor after 5 years of service.
boundaries.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 68 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – V1-Joint No.R2 Forging side W/HAZ @ 12 O’clock Position

Location_14

Sketch not to the scale Plate: 53-Weld/HAZ (100X) Plate: 54-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN

Microstructure at weld metal shows ferrite /bainite and

carbides in dendritic form. Where as at HAZ microstructure Initial level of
PM-
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 14 144, 143, 156
14. A217 WC6 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) Weld-
Initial stage of degradations in terms of carbide formation gold sputtering are
171, 166, 173
at bainite regions are observed however prior bainite kept at next page.
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 69 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- V1-Joint No.R2 Forging side W/HAZ @ 12 O’clock Position

Plate: 55-Weld/HAZ 1000X Plate: 56 -HAZ 3500X

SR.NO. SEM Observation after gold sputtering of replica

No significant presence of creep cavities observed at the grain

14 Monitor after 5 years of service.
boundaries.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 70 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – HTSH OUTLET HEADER

Location_15

Sketch not to the scale Plate: 57-Weld/HAZ (100X) Plate: 58-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
PM-
carbides in dendritic form. Where as at HAZ microstructure Initial level of
175, 180, 178
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 15 Weld-
15. A335 P12 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) 170, 168, 171
Initial stage of degradations in terms of carbide formation gold sputtering are
HAZ-
at bainite regions are observed however prior bainite kept at next page.
181, 182, 179
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 71 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- HTSH OUTLET HEADER

Plate: 59-Weld/HAZ 1000X Plate: 60 -HAZ 2000X

SR.NO. SEM Observation after gold sputtering of replica

No significant presence of creep cavities observed at the grain

15 Monitor after 5 years of service.
boundaries.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 72 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – HTSH OUTLET HEADER TUBE NO.51 Weld On Tube Side and On Base Metal of Header

Location_16

Sketch not to the scale Plate: 61-Weld/HAZ (100X) Plate: 62-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
carbides in dendritic form. Where as at HAZ microstructure Initial level of
PM-
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 16 133, 134, 128
16. A335 P22 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) Weld-
Initial stage of degradations in terms of carbide formation gold sputtering are
167, 170, 171
at bainite regions are observed however prior bainite kept at next page.
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 73 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- HTSH OUTLET HEADER TUBE NO.51 Weld On Tube Side and On Base Metal of Header

Plate: 63-Weld/HAZ 1000X Plate: 64 -HAZ 3500X

SR.NO. SEM Observation after gold sputtering of replica

No significant presence of creep cavities observed at the grain

16 Monitor after 5 years of service.
boundaries.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 74 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – LTSH OUTLET HEADER

Location_17

Sketch not to the scale Plate: 65-Weld/HAZ (100X) Plate: 66-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
PM-
carbides in dendritic form. Where as at HAZ microstructure Initial level of
125, 127, 124
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 17 Weld-
17. A335 P12 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) 176, 168, 184
Initial stage of degradations in terms of carbide formation gold sputtering are
HAZ-
at bainite regions are observed however prior bainite kept at next page.
149, 142, 147
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 75 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- LTSH OUTLET HEADER

Plate: 67-Weld/HAZ 1000X Plate: 68 -HAZ 2000X

SR.NO. SEM Observation after gold sputtering of replica

No significant presence of creep cavities observed at the grain

17 Monitor after 5 years of service.
boundaries.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 76 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – LTSH OUTLET HEADER TUBE NO.5 Weld On Tube Side and On Base Metal of Header

Location_18

Sketch not to the scale Plate: 69-Weld/HAZ (100X) Plate: 70-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
carbides in dendritic form. Where as at HAZ microstructure Initial level of
PM-
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 18 128, 127, 129
18. A335 P12 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) Weld-
Initial stage of degradations in terms of carbide formation gold sputtering are
171, 177, 180
at bainite regions are observed however prior bainite kept at next page.
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 77 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- LTSH OUTLET HEADER TUBE NO.5 Weld On Tube Side and On Base Metal of Header

Plate: 71-Weld/HAZ 1000X Plate: 72 -HAZ 3500X

SR.NO. SEM Observation after gold sputtering of replica

No significant presence of creep cavities observed at the grain

18 Monitor after 5 years of service.
boundaries.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 78 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – LTSH TUBE NO.5 RAW NO.14 Towards Rear Side Mid Zone On Parent Metal

Location_19

Sketch not to the scale Plate: 73-PM (100X) Plate: 74-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN

Initial level of
Microstructure shows fine grained essentially ferrite degradation. SEM
Location: 19 PM-
19. A213 T11 2% Nital structure with carbides at the grain boundaries and within observations after
(Parent Métal) 112, 114, 116
the grains. gold sputtering are
kept at next page.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 79 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- LTSH TUBE NO.5 RAW NO.14 Towards Rear Side Mid Zone On Parent Metal

Plate: 75-PM 1000X Plate: 76-PM 3500X

SR.NO. SEM Observation after gold sputtering of replica

No significant presence of creep cavities observed at the grain

19 Monitor after 5 years of service.
boundaries.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 80 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – LTSH TUBE NO.6 RAW NO.9 Towards Furnace Side Mid Zone On Parent Metal

Location_20

Sketch not to the scale Plate: 77-PM (100X) Plate: 78-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN

Initial level of
Microstructure shows fine grained essentially ferrite degradation. SEM
Location: 20 PM-
20. A213 T11 2% Nital structure with carbides at the grain boundaries and within observations after
(Parent Métal) 113, 114, 115
the grains. gold sputtering are
kept at next page.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 81 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- LTSH TUBE NO.6 RAW NO.9 Towards Furnace Side Mid Zone On Parent Metal

Plate: 79-PM 1000X Plate: 80 -PM 3500X

SR.NO. SEM Observation after gold sputtering of replica

No significant presence of creep cavities observed at the grain

20 Monitor after 5 years of service.
boundaries.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 82 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – LTSH TUBE NO.9 RAW NO.20 Towards Rear Side Mid Zone On Parent Metal

Location_21

Sketch not to the scale Plate: 81- PM (100X) Plate: 82-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN

Initial level of
Microstructure shows fine grained essentially ferrite degradation. SEM
Location: 21 PM-
21. A213 T11 2% Nital structure with carbides at the grain boundaries and within observations after
(Parent Métal) 117, 115 ,114
the grains. gold sputtering are
kept at next page.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 83 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- LTSH TUBE NO.9 RAW NO.20 Towards Rear Side Mid Zone On Parent Metal

Plate: 83-PM 1000X Plate: 84 -PM 3500X

SR.NO. SEM Observation after gold sputtering of replica

21 Presences of isolated creep cavities are observed. Monitor after 5 years of service.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 84 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – LTSH TUBE NO.3 RAW NO.5 Towards Furnace Side Mid Zone On Parent Metal

Location_22

Sketch not to the scale Plate: 85- PM (100X) Plate: 86-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN

Initial level of
Microstructure shows fine grained essentially ferrite degradation. SEM
Location: 22 PM-
22. A213 T11 2% Nital structure with carbides at the grain boundaries and within observations after
(Parent Métal) 110, 112, 111
the grains. gold sputtering are
kept at next page.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 85 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- LTSH TUBE NO.3 RAW NO.5 Towards Furnace Side Mid Zone On Parent Metal

Plate: 87-PM 1000X Plate: 88 -PM 3500X

SR.NO. SEM Observation after gold sputtering of replica

No significant presence of creep cavities observed at the grain

22 Monitor after 5 years of service.
boundaries.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 86 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – Joint No.B6 Elbow side W/HAZ (Replacement of R4) @ 12 O’clock Position

Location_23

Sketch not to the scale Plate: 89- Weld/HAZ (100X) Plate: 90-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
PM-
carbides in dendritic form. Where as at HAZ microstructure Initial level of
115, 116, 119
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 23 Weld-
23. A335 P11 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) 155, 159, 158
Initial stage of degradations in terms of carbide formation gold sputtering are
HAZ-
at bainite regions are observed however prior bainite kept at next page.
149, 152, 148
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 87 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- Joint No.B6 Elbow side W/HAZ (Replacement of R4) @ 12 O’clock Position

Plate: 91-Weld/HAZ 1000X Plate: 92 -HAZ 3500X

SR.NO. SEM Observation after gold sputtering of replica

23 Isolated creep cavities are observed at HAZ Monitor after 5 years of service.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 88 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – Joint No.B6 Pipe side W/HAZ (Replacement of R4) @ 12 O’clock Position

Location_24

Sketch not to the scale Plate: 93- Weld/HAZ (100X) Plate: 94-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
PM-
carbides in dendritic form. Where as at HAZ microstructure Initial level of
150, 153, 157
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 24 Weld-
24. A335 P11 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) 153, 157, 158
Initial stage of degradations in terms of carbide formation gold sputtering are
HAZ-
at bainite regions are observed however prior bainite kept at next page.
149, 151, 147
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 89 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- Joint No.B6 Pipe side W/HAZ (Replacement of R4) @ 12 O’clock Position

Plate: 95-Weld/HAZ 1000X Plate: 96 -HAZ 3500X

SR.NO. SEM Observation after gold sputtering of replica

No significant presence of creep cavities observed at the grain

24 Monitor after 5 years of service.
boundaries.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 90 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – Joint No.B2 Elbow side W/HAZ (Replacement of R9) @ 6 O’clock Position

Location_25

Sketch not to the scale Plate: 97-Weld/HAZ (100X) Plate: 98-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
PM-
carbides in dendritic form. Where as at HAZ microstructure Initial level of
135, 137, 139
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 25 Weld-
25. A335 P11 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) 176, 172, 178
Initial stage of degradations in terms of carbide formation gold sputtering are
HAZ-
at bainite regions are observed however prior bainite kept at next page.
139, 142, 145
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 91 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- Joint No.B2 Elbow side W/HAZ (Replacement of R9) @ 6 O’clock Position

Plate: 99-Weld/HAZ 1000X Plate: 100 -HAZ 3500X

SR.NO. SEM Observation after gold sputtering of replica

No significant presence of creep cavities observed at the grain

25 Monitor after 5 years of service.
boundaries.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 92 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – Joint No.B2 Elbow side W/HAZ (Replacement of R9) @ 6 O’clock Position

Location_26

Sketch not to the scale Plate: 101-Weld/HAZ (100X) Plate: 102-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
PM-
carbides in dendritic form. Where as at HAZ microstructure Initial level of
128, 125, 126
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 26 Weld-
26. A335 P11 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) 171, 177, 173
Initial stage of degradations in terms of carbide formation gold sputtering are
HAZ-
at bainite regions are observed however prior bainite kept at next page.
139, 142, 145
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 93 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- Joint No.B2 Elbow side W/HAZ (Replacement of R9) @ 6 O’clock Position

Plate: 103-Weld/HAZ 1000X Plate: 104 -HAZ 3500X

SR.NO. SEM Observation after gold sputtering of replica

26 Isolated creep cavities are observed at HAZ Monitor after 5 years of service.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 94 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – Joint No.12 Header side W/HAZ (Replacement of R5) @ 12 O’clock Position

Location_27

Sketch not to the scale Plate: 105- Weld/HAZ (100X) Plate: 106-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
PM-
carbides in dendritic form. Where as at HAZ microstructure Initial level of
112, 116, 114
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 27 Weld-
27. - 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) 112, 113, 118
Initial stage of degradations in terms of carbide formation gold sputtering are
HAZ-
at bainite regions are observed however prior bainite kept at next page.
160, 155, 157
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 95 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- Joint No.12 Header side W/HAZ (Replacement of R5) @ 12 O’clock Position

Plate: 107- Weld/HAZ 1000X Plate: 108 -HAZ 3500X

SR.NO. SEM Observation after gold sputtering of replica

No significant presence of creep cavities observed at the grain

27 Monitor after 5 years of service.
boundaries.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 96 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – Joint No.12 Elbow side W/HAZ (Replacement of R5) @ 12 O’clock Position

Location_28

Sketch not to the scale Plate: 109-Weld/HAZ (100X) Plate: 110-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
PM-
carbides in dendritic form. Where as at HAZ microstructure Initial level of
126, 124, 118
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 28 Weld-
28. - 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) 205, 203, 209
Initial stage of degradations in terms of carbide formation gold sputtering are
HAZ-
at bainite regions are observed however prior bainite kept at next page.
178, 177, 175
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 97 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- Joint No.12 Elbow side W/HAZ (Replacement of R5) @ 12 O’clock Position

Plate: 111-Weld/HAZ 1000X Plate: 112 -HAZ 3500X

SR.NO. SEM Observation after gold sputtering of replica

No significant presence of creep cavities observed at the grain

28 Monitor after 5 years of service.
boundaries.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 98 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – HT S.H Coil No.29 Tube No.F14

Location_29

Sketch not to the scale Plate: 113- Weld/HAZ (100X) Plate: 114-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
PM-
carbides in dendritic form. Where as at HAZ microstructure Initial level of
102, 101, 103
shows fine- and coarse grained ferrite-bainite structure. degradation. SEM
Location: 29 Weld-
29. A213 T22 2% Nital Parent metal shows fine-grained ferrite-bainite structure. observations after
(Weald/HAZ/PM) 123, 125, 122
Initial stage of degradations in terms of carbide formation gold sputtering are
HAZ-
at bainite regions are observed however prior bainite kept at next page.
123, 128, 129
regions are maintained.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 99 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- HT S.H Coil No.29 Tube No.F14

Plate: 115- Weld/HAZ 1000X Plate: 116 -HAZ 2000X

SR.NO. SEM Observation after gold sputtering of replica

29 Isolated creep cavities are observed at HAZ Monitor after 5 years of service.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 100 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – HT S.H Coil No.63 Tube No.F10 On Parent Metal

Location_30

Sketch not to the scale Plate: 117- PM (100X) Plate: 118-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN

Initial level of
Microstructure shows fine-grained ferrite-bainite structure.
degradation. SEM
Location: 30 Initial stage of degradations in terms of carbide formation PM-
30. A213 T11 2% Nital observations after
(Parent Métal) at bainite regions are observed however prior bainite 122, 127, 118
gold sputtering are
regions are maintained.
kept at next page.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 101 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- HT S.H Coil No.63 Tube No.F10 On Parent Metal

Plate: 119-PM 1000X Plate: 120 -PM 3500X

SR.NO. SEM Observation after gold sputtering of replica

No significant presence of creep cavities observed at the grain

30 Monitor after 5 years of service.
boundaries.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 102 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – HT S.H Coil No.25 Tube No.F12 On Parent Metal

Location_31

Sketch not to the scale Plate: 121- PM (100X) Plate: 122-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN

Initial level of
Microstructure shows fine grained essentially ferrite degradation. SEM
Location: 31 PM-
31. A213 T11 2% Nital structure with carbides at the grain boundaries and within observations after
(Parent Métal) 105, 111, 113
the grains. gold sputtering are
kept at next page.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 103 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- HT S.H Coil No.25 Tube No.F12 On Parent Metal

Plate: 123-PM 1000X Plate: 124 -PM 3500X

SR.NO. SEM Observation after gold sputtering of replica

31 Isolated creep cavities are observed at HAZ Monitor after 5 years of service.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 104 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – HT S.H Coil No.20 Tube No.F14 On Near Spacer Weld

Location_32

Sketch not to the scale Plate: 125PM (100X) Plate: 126- From PM Interface (100X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN
Microstructure at weld metal shows ferrite /bainite and
carbides in dendritic form. Initial level of
Parent metal shows fine-grained ferrite-bainite structure. degradation. SEM
Location: 32 PM-
32. A213 T22 2% Nital Initial stage of degradations in terms of carbide formation at observations after
(Weld/HAZ/PM) 107, 110, 113
bainite regions are observed however prior bainite regions gold sputtering are
are maintained. No cracking is observed at the interface. kept at next page
Fusion at interface is normal.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 105 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- HT S.H Coil No.20 Tube No.F14 On Parent Metal

Plate: 127-PM 1000X Plate: 128 -PM 3500X

SR.NO. SEM Observation after gold sputtering of replica

32 Isolated creep cavities are observed at HAZ Monitor after 5 years of service.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 106 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – HT S.H Coil No.32 Tube No.F10 On Parent Metal

Location_33

Sketch not to the scale Plate: 129- PM (100X) Plate: 130-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN

Initial level of
Microstructure shows fine grained essentially ferrite degradation. SEM
Location: 33 PM-
33. A213 T11 2% Nital structure with carbides at the grain boundaries and within observations after
(Parent Métal) 105, 111, 114
the grains. gold sputtering are
kept at next page.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 107 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
COMPONENT ID- HT S.H Coil No.32 Tube No.F10 On Parent Metal

Plate: 131- PM 1000X Plate: 132 - PM 3500X

SR.NO. SEM Observation after gold sputtering of replica

33 Isolated creep cavities are observed at HAZ Monitor after 5 years of service.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 108 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
LOCATION ID – HT S.H Coil No.41 Tube No.F14 On Parent Metal

Location_34

Sketch not to the scale Plate: 133- PM (100X) Plate: 134-PM (400X)
SR. HARDNESS
LOCATION MOC ETCHANT MICROSTRUCTURE OBSERVATION REMARK
NO. IN BHN

Initial level of
Microstructure shows fine tempered bainite structure with
degradation. SEM
Location: 34 few ferrites. Initial stage of degradations in terms of carbide PM-
34. A213 T22 2% Nital observations after
(Parent Métal) formation at bainite regions are observed however prior 141, 143, 138
gold sputtering are
bainite regions are maintained.
kept at next page.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1

DATE: 01.02.2010
MAIN STREAM LINE BOILER # 5
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL PAGE NO: 109 OF 146

COMPONENT ID- HT S.H Coil No.41 Tube No.F14 On Parent Metal

Plate: 135- PM 1000X Plate: 136 - PM 3500X

SR.NO. SEM Observation after gold sputtering of replica

34 Isolated creep cavities are observed at HAZ Monitor after 5 years of service.
Note:
1. The interpretation is done as per data supplied by Client.
2. The suggestions / recommendations expressed in the report are recommending in nature without obligation to any legal & financial implication.
3. Test certificate shall not be re-produced except in full without the written approval of laboratory.
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 110 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
HARDNESS TEST REPORT
REPORT NO : TCR /HT /001 Date :14/10/2009
PROCEDURE NO : QCP/TCR/HT/2.0 REV.0
CLIENT : SWCC, JUBAIL SKETCH: WELD
PROJECT : RLA - BOILER HT COMPONENT BASE METAL HAZ (Heat Affected Zone)
SPECIFICATION : ASME B 31. 3 & SAES - W- 011
EQUIEPMENT : HL 200 GAUGE
MATERIAL SPEC : CS
Size : SEE DWG
Welding Process : GTAW /SMAW
Hardness in BHN
Sr. No. Line No. Drawing No. Joint No. Welder No.
Location WELD HAZ Base Metal
12 O'Clock 169 160 121
R2
1 MAIN STEAM LINE V1 PH-1-MS-1-6-02 - 4 O'Clock 168 165 122
PIPE SIDE
8 O'Clock 171 162 124

12 O'Clock 170 - 147

R2
2 MAIN STEAM LINE V1 PH-1-MS-1-6-02 - 4 O'Clock 165 - 145
FORGE SIDE
8 O'Clock 172 - 140
Maximum Hardness Limit BHN
Machine Sr. Number- A122704050 Calibration verified with reference block & found acceptable.
HARDNESS TEST CARRIED OUT BY WITNESS / REVIEW WITNESS / REVIEW WITNESS / REVIEW SWCC
For TCR ARABIA COMPANY LTD. For
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 111 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
HARDNESS TEST REPORT
REPORT NO : TCR /HT /002 Date :13/10/2009
PROCEDURE NO : QCP/TCR/HT/2.0 REV.0
CLIENT : SWCC, JUBAIL SKETCH: WELD
PROJECT : RLA - BOILER HT COMPONENT BASE METAL HAZ (Heat Affected Zone)
SPECIFICATION : ASME B 31. 3 & SAES - W- 011
EQUIEPMENT : HL 200 GAUGE
MATERIAL SPEC : CS
Size : SEE DWG
Welding Process : GTAW /SMAW
Hardness in BHN
Sr. No. Line No. Drawing No. Joint No. Welder No.
Location WELD HAZ Base Metal
12 O'Clock 190 165 129
R3
1 MAIN STEAM LINE V2 PH-1-MS-1-6-02 - 4 O'Clock 195 163 132
PIPE SIDE
8 O'Clock 187 160 130

12 O'Clock 200 - 135

R3
2 MAIN STEAM LINE V2 PH-1-MS-1-6-02 - 4 O'Clock 203 - 130
FORGE SIDE
8 O'Clock 199 - 135
Maximum Hardness Limit BHN
Machine Sr. Number- A122704050 Calibration verified with reference block & found acceptable.
HARDNESS TEST CARRIED OUT BY WITNESS / REVIEW WITNESS / REVIEW WITNESS / REVIEW SWCC
For TCR ARABIA COMPANY LTD. For
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 112 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
HARDNESS TEST REPORT
REPORT NO : TCR /HT /003 Date :13/10/2009
PROCEDURE NO : QCP/TCR/HT/2.0 REV.0
SKETCH: WELD
CLIENT : SWCC, JUBAIL
PROJECT : RLA - BOILER HT COMPONENT BASE METAL HAZ (Heat Affected Zone)
SPECIFICATION : ASME B 31. 3 & SAES - W- 011
EQUIEPMENT : HL 200 GAUGE
MATERIAL SPEC : CS
Size : SEE DWG
Welding Process : GTAW /SMAW
Hardness in BHN
Sr. No. Line No. Drawing No. Joint No. Welder No.
Location WELD HAZ Base Metal
12 O'Clock 148 - 126
MAIN STEAM LINE TURBINE R10
1 PH-1-MS-1-6-02 - 4 O'Clock 152 - 130
AREA PIPE SIDE
8 O'Clock 149 - 129

12 O'Clock 145 172 129

MAIN STEAM LINE TURBINE R10
2 PH-1-MS-1-6-02 - 4 O'Clock 147 176 124
AREA FORGE SIDE
8 O'Clock 149 165 130
Maximum Hardness Limit BHN
Machine Sr. Number- A122704050 Calibration verified with reference block & found acceptable.
HARDNESS TEST CARRIED OUT BY WITNESS / REVIEW WITNESS / REVIEW WITNESS / REVIEW SWCC
For TCR ARABIA COMPANY LTD. For
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 113 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
HARDNESS TEST REPORT
REPORT NO : TCR /HT /004 Date :12/10/2009
PROCEDURE NO : QCP/TCR/HT/2.0 REV.0
CLIENT : SWCC, JUBAIL SKETCH: WELD
PROJECT : RLA - BOILER HT COMPONENT BASE METAL HAZ (Heat Affected Zone)
SPECIFICATION : ASME B 31. 3 & SAES - W- 011
EQUIEPMENT : HL 200 GAUGE
MATERIAL SPEC : CS
Size : SEE DWG
Welding Process : GTAW /SMAW
Hardness in BHN
Sr. No. Line No. Drawing No. Joint No. Welder No.
Location WELD HAZ Base Metal
12 O'Clock 162 157 134
MAIN STEAM LINE R1
1 PH-1-MS-1-6-02 - 4 O'Clock 170 150 132
B1 HT HEADER PIPE SIDE
8 O'Clock 175 149 128

12 O'Clock 161 - 138

MAIN STEAM LINE R1
2 PH-1-MS-1-6-02 - 4 O'Clock 160 - 137
B1 HT HEADER FORGE SIDE
8 O'Clock 165 - 137
Maximum Hardness Limit BHN
Machine Sr. Number- A122704050 Calibration verified with reference block & found acceptable.

HARDNESS TEST CARRIED OUT BY WITNESS / REVIEW WITNESS / REVIEW WITNESS / REVIEW SWCC
For TCR ARABIA COMPANY LTD. For
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 114 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
HARDNESS TEST REPORT
REPORT NO : TCR /HT /005 Date :12/10/2009
PROCEDURE NO : QCP/TCR/HT/2.0 REV.0
CLIENT : SWCC, JUBAIL SKETCH: WELD
PROJECT : RLA - BOILER HT COMPONENT BASE METAL HAZ (Heat Affected Zone)
SPECIFICATION : ASME B 31. 3 & SAES - W- 011
EQUIEPMENT : HL 200 GAUGE
MATERIAL SPEC : CS
Size : SEE DWG
Welding Process : GTAW /SMAW
Hardness in BHN
Sr. No. Line No. Drawing No. Joint No. Welder No.
Location WELD HAZ Base Metal
12 O'Clock 176 148 120
MAIN STEAM LINE R6
1 PH-1-MS-1-6-02 - 4 O'Clock 180 140 121
T2 PIPE SIDE
8 O'Clock 185 147 124

12 O'Clock 178 - 125

MAIN STEAM LINE R6
2 PH-1-MS-1-6-02 - 4 O'Clock 177 - 120
T2 FORGE SIDE
8 O'Clock 184 - 118
Maximum Hardness Limit BHN
Machine Sr. Number- A122704050 Calibration verified with reference block & found acceptable.
HARDNESS TEST CARRIED OUT BY WITNESS / REVIEW WITNESS / REVIEW WITNESS / REVIEW SWCC
For TCR ARABIA COMPANY LTD. For
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 115 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
HARDNESS TEST REPORT
REPORT NO : TCR /HT /006 Date :12/10/2009
PROCEDURE NO : QCP/TCR/HT/2.0 REV.0
CLIENT : SWCC, JUBAIL SKETCH: WELD
PROJECT : RLA - BOILER HT COMPONENT BASE METAL HAZ (Heat Affected Zone)
SPECIFICATION : ASME B 31. 3 & SAES - W- 011
EQUIEPMENT : HL 200 GAUGE
MATERIAL SPEC : CS
Size : SEE DWG
Welding Process : GTAW /SMAW
Hardness in BHN
Sr. No. Line No. Drawing No. Joint No. Welder No.
Location WELD HAZ Base Metal
12 O'Clock 140 157 130
MAIN STEAM LINE R7
1 PH-1-MS-1-6-02 - 4 O'Clock 134 149 126
J2 PIPE SIDE
8 O'Clock 148 148 128

12 O'Clock 146 152 109

MAIN STEAM LINE R7
2 PH-1-MS-1-6-02 - 4 O'Clock 143 157 114
J2 FORGE SIDE
8 O'Clock 148 149 115
Maximum Hardness Limit BHN
Machine Sr. Number- A122704050 Calibration verified with reference block & found acceptable.
HARDNESS TEST CARRIED OUT BY WITNESS / REVIEW WITNESS / REVIEW WITNESS / REVIEW SWCC
For TCR ARABIA COMPANY LTD. For
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 116 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
HARDNESS TEST REPORT
REPORT NO : TCR /HT /007 Date :20/10/2009
PROCEDURE NO : QCP/TCR/HT/2.0 REV.0
CLIENT : SWCC, JUBAIL SKETCH: WELD
PROJECT : RLA - BOILER HT COMPONENT BASE METAL HAZ (Heat Affected Zone)
SPECIFICATION : ASME B 31. 3 & SAES - W- 011
EQUIEPMENT : HL 200 GAUGE
MATERIAL SPEC : CS
Size : SEE DWG
Welding Process : GTAW /SMAW
Hardness in BHN
Sr. No. Line No. Drawing No. Joint No. Welder No.
Location WELD HAZ Base Metal
12 O'Clock 175 139 134
B2
1 MAIN STEAM LINE PH-1-MS-1-6-02 - 4 O'Clock 171 141 138
ELBOW SIDE
8 O'Clock 170 140 137

12 O'Clock 171 139 139

B2
2 MAIN STEAM LINE PH-1-MS-1-6-02 - 4 O'Clock 178 142 142
ELBOW SIDE
8 O'Clock 173 145 145
Maximum Hardness Limit BHN
Machine Sr. Number- A122704050 Calibration verified with reference block & found acceptable.
HARDNESS TEST CARRIED OUT BY WITNESS / REVIEW WITNESS / REVIEW WITNESS / REVIEW SWCC
For TCR ARABIA COMPANY LTD. For
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 117 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
HARDNESS TEST REPORT
REPORT NO : TCR /HT /008 Date :20/10/2009
PROCEDURE NO : QCP/TCR/HT/2.0 REV.0
CLIENT : SWCC, JUBAIL SKETCH: WELD
PROJECT : RLA - BOILER HT COMPONENT BASE METAL HAZ (Heat Affected Zone)
SPECIFICATION : ASME B 31. 3 & SAES - W- 011
EQUIEPMENT : HL 200 GAUGE
MATERIAL SPEC : CS
Size : SEE DWG
Welding Process : GTAW /SMAW
Hardness in BHN
Sr. No. Line No. Drawing No. Joint No. Welder No.
Location WELD HAZ Base Metal
12 O'Clock 154 154 118
B6
1 MAIN STEAM LINE PH-1-MS-1-6-02 - 4 O'Clock 155 151 116
ELBOW SIDE
8 O'Clock 159 150 117

12 O'Clock 152 150 125

B6
2 - PH-1-MS-1-6-02 - 4 O'Clock 156 152 128
PIPE SIDE
8 O'Clock 154 147 127
Maximum Hardness Limit BHN
Machine Sr. Number- A122704050 Calibration verified with reference block & found acceptable.
HARDNESS TEST CARRIED OUT BY WITNESS / REVIEW WITNESS / REVIEW WITNESS / REVIEW SWCC
For TCR ARABIA COMPANY LTD. For
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 118 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
HARDNESS TEST REPORT
REPORT NO : TCR /HT /009 Date :17/10/2009
PROCEDURE NO : QCP/TCR/HT/2.0 REV.0
CLIENT : SWCC, JUBAIL SKETCH: WELD
PROJECT : RLA - BOILER HT COMPONENT BASE METAL HAZ (Heat Affected Zone)
SPECIFICATION : ASME B 31. 3 & SAES - W- 011
EQUIEPMENT : HL 200 GAUGE
MATERIAL SPEC : CS
Size : SEE DWG
Welding Process : GTAW /SMAW
Hardness in BHN
Sr. No. Line No. Drawing No. Joint No. Welder No.
Location WELD HAZ Base Metal
12 O'Clock - - 116
LTSH ROW-20
1 LTSH PH-1-MS-1-6-02 - 4 O'Clock - - 113
TUBE-9
8 O'Clock - - 114

12 O'Clock - - 111
LTSH ROW-5
2 LTSH PH-1-MS-1-6-02 - 4 O'Clock - - 110
TUBE-3
8 O'Clock - - 113
Maximum Hardness Limit BHN
Machine Sr. Number- A122704050 Calibration verified with reference block & found acceptable.
HARDNESS TEST CARRIED OUT BY WITNESS / REVIEW WITNESS / REVIEW WITNESS / REVIEW SWCC
For TCR ARABIA COMPANY LTD. For
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 119 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
HARDNESS TEST REPORT
REPORT NO : TCR /HT /010 Date :17/10/2009
PROCEDURE NO : QCP/TCR/HT/2.0 REV.0
CLIENT : SWCC, JUBAIL SKETCH: WELD
PROJECT : RLA - BOILER HT COMPONENT BASE METAL HAZ (Heat Affected Zone)
SPECIFICATION : ASME B 31. 3 & SAES - W- 011
EQUIEPMENT : HL 200 GAUGE
MATERIAL SPEC : CS
Size : SEE DWG
Welding Process : GTAW /SMAW
Hardness in BHN
Sr. No. Line No. Drawing No. Joint No. Welder No.
Location WELD HAZ Base Metal
12 O'Clock - - 112
LTSH ROW-14
1 LTSH PH-1-MS-1-6-02 - 4 O'Clock - - 114
TUBE-5
8 O'Clock - - 115

12 O'Clock - - 114
LTSH ROW-9
2 LTSH PH-1-MS-1-6-02 - 4 O'Clock - - 115
TUBE-6
8 O'Clock - - 118
Maximum Hardness Limit BHN
Machine Sr. Number- A122704050 Calibration verified with reference block & found acceptable.
HARDNESS TEST CARRIED OUT BY WITNESS / REVIEW WITNESS / REVIEW WITNESS / REVIEW SWCC
For TCR ARABIA COMPANY LTD. For
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 120 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
HARDNESS TEST REPORT
REPORT NO : TCR /HT /011 Date :15/10/2009
PROCEDURE NO : QCP/TCR/HT/2.0 REV.0
CLIENT : SWCC, JUBAIL SKETCH: WELD
PROJECT : RLA - BOILER HT COMPONENT BASE METAL HAZ (Heat Affected Zone)
SPECIFICATION : ASME B 31. 3 & SAES - W- 011
EQUIEPMENT : HL 200 GAUGE
MATERIAL SPEC : CS
Size : SEE DWG
Welding Process : GTAW /SMAW
Hardness in BHN
Sr. No. Line No. Drawing No. Joint No. Welder No.
Location WELD HAZ Base Metal
12 O'Clock 169 140 123
LTSH Outlet
1 LTSH PH-1-MS-1-6-02 Header - 4 O'Clock 177 145 125
Middle Weld
8 O'Clock 181 147 126

LTSH Outlet 12 O'Clock 170 - 126

Header
2 LTSH PH-1-MS-1-6-02 - 4 O'Clock 179 - 127
TUBE-5
Middle Weld 8 O'Clock 183 - 129
Maximum Hardness Limit BHN
Machine Sr. Number- A122704050 Calibration verified with reference block & found acceptable.
HARDNESS TEST CARRIED OUT BY WITNESS / REVIEW WITNESS / REVIEW WITNESS / REVIEW SWCC
For TCR ARABIA COMPANY LTD. For
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 121 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
HARDNESS TEST REPORT
REPORT NO : TCR /HT /012 Date :15/10/2009
PROCEDURE NO : QCP/TCR/HT/2.0 REV.0
CLIENT : SWCC, JUBAIL SKETCH: WELD
PROJECT : RLA - BOILER HT COMPONENT BASE METAL HAZ (Heat Affected Zone)
SPECIFICATION : ASME B 31. 3 & SAES - W- 011
EQUIEPMENT : HL 200 GAUGE
MATERIAL SPEC : CS
Size : SEE DWG
Welding Process : GTAW /SMAW
Hardness in BHN
Sr. No. Line No. Drawing No. Joint No. Welder No.
Location WELD HAZ Base Metal
12 O'Clock 170 187 182
HTSH Outlet
1 HTSH PH-1-MS-1-6-02 Header - 4 O'Clock 166 178 187
Middle Weld
8 O'Clock 167 182 170

HTSH Outlet 12 O'Clock 170 - 131

Header
2 HTSH PH-1-MS-1-6-02 - 4 O'Clock 177 - 132
TUBE-51
Middle Weld 8 O'Clock 173 - 129
Maximum Hardness Limit BHN
Machine Sr. Number- A122704050 Calibration verified with reference block & found acceptable.
HARDNESS TEST CARRIED OUT BY WITNESS / REVIEW WITNESS / REVIEW WITNESS / REVIEW SWCC
For TCR ARABIA COMPANY LTD. For
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 122 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
HARDNESS TEST REPORT
REPORT NO : TCR /HT /013 Date :12/10/2009
PROCEDURE NO : QCP/TCR/HT/2.0 REV.0
CLIENT : SWCC, JUBAIL SKETCH: WELD
PROJECT : RLA - BOILER HT COMPONENT BASE METAL HAZ (Heat Affected Zone)
SPECIFICATION : ASME B 31. 3 & SAES - W- 011
EQUIEPMENT : HL 200 GAUGE
MATERIAL SPEC : CS
Size : SEE DWG
Welding Process : GTAW /SMAW
Hardness in BHN
Sr. No. Line No. Drawing No. Joint No. Welder No.
Location WELD HAZ Base Metal
12 O'Clock 144 154 118
R8
1 MAIN STEAM LINE Y1 PH-1-MS-1-6-02 - 4 O'Clock 147 143 119
PIPE SIDE
8 O'Clock 150 147 115

12 O'Clock 141 150 111

R8
2 MAIN STEAM LINE Y1 PH-1-MS-1-6-02 - 4 O'Clock 155 149 110
FORGE SIDE
8 O'Clock 140 148 109
Maximum Hardness Limit BHN
Machine Sr. Number- A122704050 Calibration verified with reference block & found acceptable.
HARDNESS TEST CARRIED OUT BY WITNESS / REVIEW WITNESS / REVIEW WITNESS / REVIEW SWCC
For TCR ARABIA COMPANY LTD. For
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 123 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
HARDNESS TEST REPORT
REPORT NO : TCR /HT /014 Date :22/10/2009
PROCEDURE NO : QCP/TCR/HT/2.0 REV.0
CLIENT : SWCC, JUBAIL SKETCH: WELD
PROJECT : RLA - BOILER HT COMPONENT BASE METAL HAZ (Heat Affected Zone)
SPECIFICATION : ASME B 31. 3 & SAES - W- 011
EQUIEPMENT : HL 200 GAUGE
MATERIAL SPEC : CS
Size : SEE DWG
Welding Process : GTAW /SMAW
Hardness in BHN
Sr. No. Line No. Drawing No. Joint No. Welder No.
Location WELD HAZ Base Metal
12 O'Clock 213 161 113
R12
1 MAIN STEAM LINE PH-1-MS-1-6-02 - 4 O'Clock 210 154 117
HEADER SIDE
8 O'Clock 218 158 115

12 O'Clock 205 177 127

R12
2 MAIN STEAM LINE PH-1-MS-1-6-02 - 4 O'Clock 204 172 125
ELBOW SIDE
8 O'Clock 208 174 120
Maximum Hardness Limit BHN
Machine Sr. Number- A122704050 Calibration verified with reference block & found acceptable.
HARDNESS TEST CARRIED OUT BY WITNESS / REVIEW WITNESS / REVIEW WITNESS / REVIEW SWCC
For TCR ARABIA COMPANY LTD. For
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 124 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
HARDNESS TEST REPORT
REPORT NO : TCR /HT /015 Date :26/10/2009
PROCEDURE NO : QCP/TCR/HT/2.0 REV.0
CLIENT : SWCC, JUBAIL SKETCH: WELD
PROJECT : RLA - BOILER HT COMPONENT BASE METAL HAZ (Heat Affected Zone)
SPECIFICATION : ASME B 31. 3 & SAES - W- 011
EQUIEPMENT : HL 200 GAUGE
MATERIAL SPEC : CS
Size : SEE DWG
Welding Process : GTAW /SMAW
Hardness in BHN
Sr. No. Line No. Drawing No. Joint No. Welder No.
Location WELD HAZ Base Metal
12 O'Clock 124 122 102
COIL NO.29
1 HTSH PH-1-MS-1-6-02 - 4 O'Clock 125 128 104
TUBE NO.F14
8 O'Clock 121 131 105

12 O'Clock - - 123
COIL NO.63
2 HTSH PH-1-MS-1-6-02 - 4 O'Clock - - 126
TUBE NO.F10
8 O'Clock - - 119
Maximum Hardness Limit BHN
Machine Sr. Number- A122704050 Calibration verified with reference block & found acceptable.
HARDNESS TEST CARRIED OUT BY WITNESS / REVIEW WITNESS / REVIEW WITNESS / REVIEW SWCC
For TCR ARABIA COMPANY LTD. For
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 125 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
HARDNESS TEST REPORT
REPORT NO : TCR /HT /016 Date :26/10/2009
PROCEDURE NO : QCP/TCR/HT/2.0 REV.0
CLIENT : SWCC, JUBAIL SKETCH: WELD
PROJECT : RLA - BOILER HT COMPONENT BASE METAL HAZ (Heat Affected Zone)
SPECIFICATION : ASME B 31. 3 & SAES - W- 011
EQUIEPMENT : HL 200 GAUGE
MATERIAL SPEC : CS
Size : SEE DWG
Welding Process : GTAW /SMAW
Hardness in BHN
Sr. No. Line No. Drawing No. Joint No. Welder No.
Location WELD HAZ Base Metal
12 O'Clock - - 110
COIL NO.25
1 HTSH PH-1-MS-1-6-02 - 4 O'Clock - - 112
TUBE NO.F12
8 O'Clock - - 107

12 O'Clock - - 106
COIL NO.20
2 HTSH PH-1-MS-1-6-02 - 4 O'Clock - - 109
TUBE NO.F14
8 O'Clock - - 112
Maximum Hardness Limit BHN
Machine Sr. Number- A122704050 Calibration verified with reference block & found acceptable.
HARDNESS TEST CARRIED OUT BY WITNESS / REVIEW WITNESS / REVIEW WITNESS / REVIEW SWCC
For TCR ARABIA COMPANY LTD. For
 TCR ARABIA COMPANY LIMITED REPORT NO: TCR/002/10/RLA

IN-SITU METALLOGRAPHY, HARDNESS & SEM WORK OF PHASE-1 DATE: 01.02.2010

MAIN STREAM LINE BOILER # 5
PAGE NO: 126 OF 146
CLIENT: SALINE WATER CONVERSION CORPORATION, JUBAIL
HARDNESS TEST REPORT
REPORT NO : TCR /HT /017 Date :26/10/2009
PROCEDURE NO : QCP/TCR/HT/2.0 REV.0
CLIENT : SWCC, JUBAIL SKETCH: WELD
PROJECT : RLA - BOILER HT COMPONENT BASE METAL HAZ (Heat Affected Zone)
SPECIFICATION : ASME B 31. 3 & SAES - W- 011
EQUIEPMENT : HL 200 GAUGE
MATERIAL SPEC : CS
Size : SEE DWG
Welding Process : GTAW /SMAW
Hardness in BHN
Sr. No. Line No. Drawing No. Joint No. Welder No.
Location WELD HAZ Base Metal
12 O'Clock - - 106
COIL NO.32
1 HTSH PH-1-MS-1-6-02 - 4 O'Clock - - 112
TUBE NO.F10
8 O'Clock - - 113

12 O'Clock - - 142
COIL NO.41
2 HTSH PH-1-MS-1-6-02 - 4 O'Clock - - 144
TUBE NO.F14
8 O'Clock - - 139
Maximum Hardness Limit BHN
Machine Sr. Number- A122704050 Calibration verified with reference block & found acceptable.

HARDNESS TEST CARRIED OUT BY WITNESS / REVIEW WITNESS / REVIEW WITNESS / REVIEW SWCC
For TCR ARABIA COMPANY LTD. For
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5 Page 127 of 146

MAGNETIC PARTICLE EXAMINATION REPORT

Client SWCC JUBAIL

Procedure No QCP/TCR/MPI/01 Rev 01 Date 12/10/2009
Job Order No RR No-26263
Report No TCR/MPT/001
Drawing No. PH1-MS-1-6-02
Inspection Date 12/10/2009
Test Material CS
Surface condition As welded √ As rolled
Surface Temperature Ambient
Object To detect surface / sub-surface discontinuities
Test Equipment Electromagnetic Yoke Make& Model Sr.No.
CONTOUR PROBE 17345
Test Technique Continuous Method: Wet √  A
Dry
Residual Method : Wet Dry
Magnetic Particles Non-Fluorescent (Visible) Fluorescent √
Test Carried out Before PWHT After PWHT
Magnetizing current AC √ HWDC DC √
Inspection Under Visible light: Artificial light: Ultra Violet light √
Applicable Reference ASME Sec. V, Article 7
Acceptance Standard ASME B31.1/ASME SEC VIII Div.1
Calibration For AC: 4.5 Kgs (10 Lbs.)
(Lifting Capacity) For DC: 18.1 Kgs. (40 Lbs.)
T e st Re s u lt : MA IN S TE A M LI N E PH A SE 1 U NI T #5
Sl. No De s cr ip t ion Ob se r vat ion Re su lt Re m ark s
1 B1 E LB OW ( 1 JO IN TS ) NRI AC CE PT A BLE
2 B2 E LB OW ( 2 JO IN TS ) NRI AC CE PT A BLE

For T C R AR AB IA In s p e ct ion Au th o ri ty Cl ie n t:
N am e : R . Sr id h ar N am e : Nam e :
Qu al if i cati on : M T l e ve l -I I De s ign ati on : De s ign ati on :
Si gn : Si gn : Si gn :
Dat e : 12/10/2009 Dat e : Dat e :
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5 Page 128 of 146

MAGNETIC PARTICLE EXAMINATION REPORT

Client SWCC JUBAIL

Procedure No QCP/TCR/MPI/01 Rev 01 Date 13/10/2009
Job Order No. RR-No: 26263
Report No TCR/MPT/002
Drawing No. PH1-MS-1-6-02
Inspection Date 13/10/2009
Test Material CS
Surface condition As welded √ As rolled
Surface Temperature Ambient
Object To detect surface / sub-surface discontinuities
Test Equipment Electromagnetic Yoke Make& Model Sr.No.
CONTOUR PROBE 17345

A√
Test Technique Continuous Method: Wet Dry
Residual Method : Wet Dry
Magnetic Particles Non-Fluorescent (Visible) Fluorescent √
Test Carried out Before PWHT After PWHT
Magnetizing current AC √ HWDC DC √
Inspection Under Visible light: Artificial light: Ultra Violet light √
Applicable Reference ASME Sec. V, Article 7
Acceptance Standard ASME B31.1/ASME SEC VIII Div.1
Calibration For AC: 4.5 Kgs (10 Lbs.)
(Lifting Capacity) For DC: 18.1 Kgs. (40 Lbs.)
T e st Re s u lt : MA IN S TE A M LI N E PH A SE 1 U NI T #5
Sl. No De s cr ip t ion Ob se r vat ion Re su lt Re m ark s
1 B3 E LB OW ( 2 JO IN TS ) NRI AC CE PT A BLE
2 V1 V AL VE ( 2 J OIN T S) NRI AC CE PT A BLE V1, R2 Join t Ha l f
Port ion on ly MP I
Don e.

For T C R AR AB IA In s p e ct ion Au th o ri ty Cl ie n t:
Nam e : L AX MI K AN T N am e : Nam e :
Qu al if i cati on : M T l e ve l -I I De s ign ati on : De s ign ati on :
Si gn : Si gn : Si gn :
Dat e : 29/07/2009 Dat e : 29/07/2009 Dat e :
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5 Page 129 of 146

MAGNETIC PARTICLE EXAMINATION REPORT

Client SWCC JUBAIL

Procedure No QCP/TCR/MPI/01 Rev01 Date 14-10-2009
Job Order No RR-No-26263
Report No TCR/MPT/003
Drawing No. PH1-MS-1-6-02
Inspection Date 14-10-2009
Test Material CS
Surface condition As welded √ As rolled
Surface Temperature Ambient
Object To detect surface / sub-surface discontinuities
Test Equipment Electromagnetic Yoke Make& Model Sr.No.
CONTOUR PROBE 17345
Test Technique Continuous Method: Wet √
A
Dry
Residual Method : Wet Dry
Magnetic Particles Non-Fluorescent (Visible) Fluorescent √
Test Carried out Before PWHT After PWHT
Magnetizing current AC √ HWDC DC √
Inspection Under Visible light: Artificial light: Ultra Violet light √
Applicable Reference ASME Sec. V, Article 7
Acceptance Standard ASME B31.1/ASME SEC VIII Div.1
Calibration For AC: 4.5 Kgs (10 Lbs.)
(Lifting Capacity) For DC: 18.1 Kgs. (40 Lbs.)
T e st Re s u lt : MA IN S TE A M LI N E PH A SE 1 U NI T #5
Sl. No De s cr ip t ion Ob se r vat ion Re su lt Re m ark s
1 V4 V AL V E ( 2 JO IN TS ) NRI AC CE PT A BLE
2 B4 E LB OW ( 2 JO IN TS ) NRI AC CE PT A BLE

Note : N RI –N o Re l e van t In d i cat ion s

For T C R AR AB IA In s p e ct ion Au th o ri ty Cl ie n t:
Nam e : R. Sr id h ar N am e : Nam e :
Qu al if i cati on : M T l e ve l -I I De s ign ati on : De s ign ati o n :
Si gn : Si gn : Si gn :
Dat e :1 4 -1 0 -2 00 9 Dat e : Dat e :
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5 Page 130 of 146

MAGNETIC PARTICLE EXAMINATION REPORT

Client SWCC JUBAIL

Procedure No QCP/TCR/MPI/01 Rev 01 Date 15/10/2009
Job Order NO RR-N0-26263
Report No TCR/MPT/004
Drawing No. PH1-MS-1-6-02
Inspection Date 15/10/2009
Test Material CS
Surface condition As welded √ As rolled
Surface Temperature Ambient
Object To detect surface / sub-surface discontinuities
Test Equipment Electromagnetic Yoke Make& Model Sr.No.
CONTOUR PROBE 17345

A√
Test Technique Continuous Method: Wet Dry
Residual Method : Wet Dry
Magnetic Particles Non-Fluorescent (Visible) Fluorescent √
Test Carried out Before PWHT After PWHT
Magnetizing current AC √ HWDC DC √
Inspection Under Visible light: Artificial light: Ultra Violet light √
Applicable Reference ASME Sec. V, Article 7
Acceptance Standard ASME B31.1/ASME SEC VIII Div.1
Calibration For AC: 4.5 Kgs (10 Lbs.)
(Lifting Capacity) For DC: 18.1 Kgs. (40 Lbs.)
T e st Re s u lt : MA IN S TE A M LI N E PH A SE 1 U NI T #5
Sl. No De s cr ip t ion Ob se r vat ion Re su lt Re m ark s
1 B5 E LB OW ( 2 JO IN TS ) NRI AC CE PT A BLE
2 B 6 E L BO W( 2 J OIN T S ) NRI AC CE PT A BLE
3 C1 R ed u c er (2 Jo in t s ) NRI AC CE PT A BLE
4 T 2 Te e ( 2 Joi n t s) NRI AC CE PT A BLE

For T C R AR AB IA In s p e ct ion Au th o ri ty Cl ie n t:
Nam e R. Sr id h a r N am e : Nam e :
Qu al if i cati on : M T l e ve l -I I De s ign ati on : De s ign ati on :
Si gn : Si gn : Si gn :
Dat e :1 5 -1 0 -2 00 9 Dat e : Dat e :
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5 Page 131 of 146

MAGNETIC PARTICLE EXAMINATION REPORT

Client SWCC JUBAIL

Procedure No QCP/TCR/MPI/01 Rev 01 Date 17/10/2009
Report No TCR/MPT/005
Job Order No RR-No-26263
Drawing No. PH1-MS-1-6-02
Inspection Date 17/10/2009
Test Material CS
Surface condition As welded √ As rolled
Surface Temperature Ambient
Object To detect surface / sub-surface discontinuities
Test Equipment Electromagnetic Yoke Make& Model Sr.No.
CONTOUR PROBE 17345

A√
Test Technique Continuous Method: Wet Dry
Residual Method : Wet Dry
Magnetic Particles Non-Fluorescent (Visible) Fluorescent √
Test Carried out Before PWHT After PWHT
Magnetizing current AC √ HWDC DC √
Inspection Under Visible light: Artificial light: Ultra Violet light √
Applicable Reference ASME Sec. V, Article 7
Acceptance Standard ASME B31.1/ASME SEC VIII Div.1
Calibration For AC: 4.5 Kgs (10 Lbs.)
(Lifting Capacity) For DC: 18.1 Kgs. (40 Lbs.)
T e st Re s u lt : MA IN S TE A M LI N E PH A SE 1 U NI T #5
Sl. No De s cr ip t ion Ob se r vat ion Re su lt Re m ark s
1 V4 V AL VE ( 1 - JO IN TS ) NRI AC CE PT A BLE
2 Y 1 ( 3 - JO IN TS ) NRI AC CE P T A BLE
3 B1 1 E L B OW (1 J OIN T S ) NRI AC CE PT A BLE
4 B1 2 E L B OW (1 J OIN T S ) NRI AC CE PT A BLE
5 HT SH IN LE T HE A DE R - 2 J T S. NRI AC CE PT A BLE
6 LOWE R TE MP. HE A DE R -2 J T S. NRI AC CE PT A BLE

For T C R AR AB IA In s p e ct ion Au th o ri ty Cl ie n t:
Nam e : R. SR IDH A R N am e : Nam e :
Qu a l if i cati on : M T l e ve l -I I De s ign ati on : De s ign ati on :
Si gn : Si gn : Si gn :
Dat e :1 7/ 1 0/ 20 09 Dat e : Dat e :
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5 Page 132 of 146

MAGNETIC PARTICLE EXAMINATION REPORT

Client SWCC JUBAIL

Procedure No QCP/TCR/MPI/01 Rev 01 Date 20/10/2009
Job Order No RR-N0-26263
Report No TCR/MPT/006
Drawing No. -------
Inspection Date 20/10/2009
Test Material ASTM A355 P12 & P22 (High temp. Super Heater)
Surface condition As welded √ As rolled
Surface Temperature Ambient
Object To detect surface / sub-surface discontinuities
Test Equipment Electromagnetic Yoke Make& Model Sr.No.
CONTOUR PROBE 17345
Test Technique Continuous Method: Wet √
A
Dry
Residual Method : Wet Dry
Magnetic Particles Non-Fluorescent (Visible) Fluorescent √
Test Carried out Before PWHT After PWHT
Magnetizing current AC √ HWDC DC √
Inspection Under Visible light: Artificial light: Ultra Violet light √
Applicable Reference ASME Sec. V, Article 7
Acceptance Standard ASME B31.1/ASME SEC VIII Div.1
Calibration For AC: 4.5 Kgs (10 Lbs.)
(Lifting Capacity) For DC: 18.1 Kgs. (40 Lbs.)
T e st Re s u lt : MA IN S TE A M LI N E PH A SE 1 U NI T #5 Hea d e r
Sl. No De s c r ip t ion Ob se r vat ion Re su lt Re m ark s
1 HT SH O U TLE T HE AD E R S T UB S MPI D ONE
1A /B, 2 B,3 A/ B, 4A / B,5 A/ B,6 B, 7A /B , ONL Y ON
NRI AC CE PT A BLE
8A /B, 9 A,1 0A / B,1 1 B,1 2A /B, 13 A /B, 14 A /B AC CE SS IB LE
15 A/ B, 16 A/ B, 17 A/ B 18 A/ B, ARE A
19 A/ B, 20 A/ B, 21 A/ B

For T C R AR AB IA In s p e ct ion Au th o ri ty Cl ie n t:
Nam e : R . SR IDH A R N am e : Nam e :
Qu al if i cati on : M T l e ve l -I I De s ign ati on : De s ign ati on :
Si gn : Si gn : Si gn :
Dat e :2 0/ 1 0/ 20 09 Dat e : Dat e :
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5 Page 133 of 146

MAGNETIC PARTICLE EXAMINATION REPORT

Client SWCC JUBAIL

Procedure No QCP/TCR/MPI/01 Rev 01 Date 20/10/2009
Job Order No RR-N0-26263
Report No TCR/MPT/007
Drawing No. ----------------------
Inspection Date 20/10/2009
Test Material ASTM A355 P12 & P22 (High temp. Super Heater)
Surface condition As welded √ As rolled
Surface Temperature Ambient
Object To detect surface / sub-surface discontinuities
Test Equipment Electromagnetic Yoke Make& Model Sr.No.
CONTOUR PROBE 17345
Test Technique Continuous Method: Wet √
A
Dry
Residual Method : Wet Dry
Magnetic Particles Non-Fluorescent (Visible) Fluorescent √
Test Carried out Before PWHT After PWHT
Magnetizing current AC √ HWDC DC √
Inspection Under Visible light: Artificial light: Ultra Violet light √
Applicable Reference ASME Sec. V, Article 7
Acceptance Standard ASME B31.1/ASME SEC VIII Div.1
Calibration For AC: 4.5 Kgs (10 Lbs.)
(Lifting Capacity) For DC: 18.1 Kgs. (40 Lbs.)
T e st Re s u lt : MA IN S TE A M LI N E PH A SE 1 U NI T #5 Hea d e r
Sl. No De s cr ip t ion Ob se r vat ion Re su lt Re m ark s
1 HT SH O U TLE T HE AD E R S T UB S MPI D ONE
22 A,2 3 A,2 4A / B,2 5A / B,2 6A /B, 2 7A /B ONL Y
NRI AC CE PT A BLE
28 A/ B, 29 A/ B, 30 A/ B, 31 A /B, 32 A /B, 33 A /B AC CE SS IB LE
34 A/ B, 35 A,3 6 A/ B,3 7 B,3 8A /B, 3 9A /B . ARE A

For T C R AR AB IA In s p e ct ion Au th o ri ty Cl ie n t:
Nam e : R . SR IDH A R N am e : Nam e :
Qu al if i cati on : M T l e ve l -I I De s ign ati on : De s ign ati on :
Si gn : Si gn : Si gn :
Dat e :2 0/ 1 0/ 20 09 Dat e : Dat e :
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5 Page 134 of 146

MAGNETIC PARTICLE EXAMINATION REPORT

Client SWCC JUBAIL

Procedure No QCP/TCR/MPI/01 Rev 01 Date 20/10/2009
Job Order No RR-N0-26263
Report No TCR/MPT/008
Drawing No. --------------
Inspection Date 20/10/2009
Test Material ASTM A355 P12 & P22 (High temp. Super Heater)
Surface condition As welded √ As rolled
Surface Temperature Ambient
Object To detect surface / sub-surface discontinuities
Test Equipment Electromagnetic Yoke Make& Model Sr.No.
CONTOUR PROBE 17345
Test Technique Continuous Method: Wet √
A
Dry
Residual Method : Wet Dry
Magnetic Particles Non-Fluorescent (Visible) Fluorescent √
Test Carried out Before PWHT After PWHT
Magnetizing current AC √ HWDC DC √
Inspection Under Visible light: Artificial light: Ultra Violet light √
Applicable Reference ASME Sec. V, Article 7
Acceptance Standard ASME B31.1/ASME SEC VIII Div.1
Calibration For AC: 4.5 Kgs (10 Lbs.)
(Lifting Capacity) For DC: 18.1 Kgs. (40 Lbs.)
T e st Re s u lt : MA IN S TE A M LI N E PH A SE 1 U NI T #5 Hea d e r
Sl. No De s cr ip t ion Ob se r vat ion Re su lt Re m ark s
01 H TS H O UT L E T H EA D E R S TUB S : NRI AC CE PT A BLE
40 A,4 1 A/ B,4 2 B,4 3A ,4 4A ,45 B
02 H TS H O UT L E T H EA D E R S TUB S : NRI AC CE PT A BLE
02 N o s Jo i n t Re p la c e me n t o f B 7

For T C R AR AB IA In s p e ct ion Au th o ri ty Cl ie n t:
Nam e : R iz wan d e sai N am e : Nam e :
Qu al if i cati on : M T l e ve l -I I De s ign ati on : De s ign ati on :
Si gn : Si gn : Si gn :
Dat e :2 0/ 1 0/ 20 09 Dat e : Dat e :
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5 Page 135 of 146

MAGNETIC PARTICLE EXAMINATION REPORT

Client SWCC JUBAIL

Procedure No QCP/TCR/MPT/01 Rev01 Date 19/10/2009
Job Order No RR-N0-26263
Report No TCR/MPI/009
Drawing No. -----------------
Inspection Date 19/10/2009
Test Material ASTM A355 P12 (Low Temp. Super Heater)
Surface condition As welded √ As rolled
Surface Temperature Ambient
Object To detect surface / sub-surface discontinuities
Test Equipment Electromagnetic Yoke Make& Model Sr.No.
CONTOUR PROBE 17345

A√
Test Technique Continuous Method: Wet Dry
Residual Method : Wet Dry
Magnetic Particles Non-Fluorescent (Visible) Fluorescent √
Test Carried out Before PWHT After PWHT
Magnetizing current AC √ HWDC DC √
Inspection Under Visible light: Artificial light: Ultra Violet light √
Applicable Reference ASME Sec. V, Article 7
Acceptance Standard ASME B31.1/ASME SEC VIII Div.1
Calibration For AC: 4.5 Kgs (10 Lbs.)
(Lifting Capacity) For DC: 18.1 Kgs. (40 Lbs.)
T e st Re s u lt : MA IN S TE A M LI N E PH A SE 1 U NI T #5
Sl. No De s cr ip t ion Ob se r vat ion Re su lt Re m ark s
01 H TS H IN L ET H EA D ER : NRI AC CE PT A BLE MPI D ONE O NL Y
T UBE N O :3 4 A,3 5A ,3 6A, 3 7A, 3 AC CE SS IB LE
38 A,3 9 A,4 0A, 4 1A, 42 A, 4 3A ARE A
44 A, 45 A.
02 HT SH IN LE T HE A DE R (0 2 )
Nos J oin t. Re p la c e me n t
Of B 8.

For T C R AR AB IA In s p e ct ion Au th o ri ty Cl ie n t:
Nam e : R iz wan D e sa i N am e : Nam e :
Qu al if i cati on : M T l e ve l -I I De s ign ati on : De s ign ati on :
Si gn : Si gn : Si gn :
Dat e :1 9/ 1 0/ 20 09 Dat e : Dat e :
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5 Page 136 of 146

MAGNETIC PARTICLE EXAMINATION REPORT

Client SWCC JUBAIL

Procedure No QCP/TCR/MPT/01 Rev01 Date 19/10/2009
Job Order No RR-N0-26263
Report No TCR/MPI/010
Drawing No. -----------------
Inspection Date 19/10/2009
Test Material ASTM A355 P12 (Low Temp. Super Heater)
Surface condition As welded √ As rolled
Surface Temperature Ambient
Object To detect surface / sub-surface discontinuities
Test Equipment Electromagnetic Yoke Make& Model Sr.No.
CONTOUR PROBE 17345

A√
Test Technique Continuous Method: Wet Dry
Residual Method : Wet Dry
Magnetic Particles Non-Fluorescent (Visible) Fluorescent √
Test Carried out Before PWHT After PWHT
Magnetizing current AC √ HWDC DC √
Inspection Under Visible light: Artificial light: Ultra Violet light √
Applicable Reference ASME Sec. V, Article 7
Acceptance Standard ASME B31.1/ASME SEC VIII Div.1
Calibration For AC: 4.5 Kgs (10 Lbs.)
(Lifting Capacity) For DC: 18.1 Kgs. (40 Lbs.)
T e st Re s u lt : MA IN S TE A M LI N E PH A SE 1 U NI T #5
Sl. No De s cr ip t ion Ob se r vat ion Re su lt Re m ark s
01 H TS H IN L ET H E A D ER S T UB S: MPI D ONE O NL Y
1A, 2A ,3 A,4 A, 5A, 6 A ,7 A,8 A,9 A AC CE SS IB LE
10 A,1 1 A,1 2A, 1 3A, 14 A, 1 5A, 16 A, ARE A
NRI AC CE PT A BLE
17 A,1 8 A,1 9A, 2 0A, 21 A, 2 2A, 23 A,
24 A,2 5 A,2 6A, 2 7A, 28 A, 2 9A, 30 A
31 A, 32 A, 33 A.

For T C R AR AB IA In s p e ct ion Au th o ri ty Cl ie n t:
Nam e : R iz wan D e sa i N am e : Nam e :
Qu al if i cati on : M T l e ve l -I I De s ign ati on : De s ign ati on :
Si gn : Si gn : Si gn :
Dat e :1 9/ 1 0/ 20 09 Dat e : Dat e :
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5 Page 137 of 146

MAGNETIC PARTICLE EXAMINATION REPORT

Client SWCC JUBAIL

Procedure No QCP/TCR/MPT/01 Rev01 Date 19/10/2009
Job Order No RR-N0-26263
Report No TCR/MPI/011
Drawing No. -----------------
Inspection Date 19/10/2009
Test Material ASTM A355 P12 (Low Temp. Super Heater)
Surface condition As welded √ As rolled
Surface Temperature Ambient
Object To detect surface / sub-surface discontinuities
Test Equipment Electromagnetic Yoke Make& Model Sr.No.
CONTOUR PROBE 17345

A√
Test Technique Continuous Method: Wet Dry
Residual Method : Wet Dry
Magnetic Particles Non-Fluorescent (Visible) Fluorescent √
Test Carried out Before PWHT After PWHT
Magnetizing current AC √ HWDC DC √
Inspection Under Visible light: Artificial light: Ultra Violet light √
Applicable Reference ASME Sec. V, Article 7
Acceptance Standard ASME B31.1/ASME SEC VIII Div.1
Calibration For AC: 4.5 Kgs (10 Lbs.)
(Lifting Capacity) For DC: 18.1 Kgs. (40 Lbs.)
T e st Re s u lt : MA IN S TE A M LI N E PH A SE 1 U NI T #5
Sl. No De s cr ip t ion Ob se r vat ion Re su lt Re m ark s
01 Lo we r T e mp . He ad e r Stu b s : NRI AC CE PT A BLE MPI D ONE O NL Y
1A .2 A. 3A .4 A. 5A .6 A. 7A .8 A, AC CE SS IB LE
9A, 10 A, 11 A,1 2 A,1 3A ,1 4 A, ARE A
15 A,1 6 A,1 7A, 1 8A, 19 A, 2 0A
21 A, 22 A.
02 Lo we r T e mp . He ad e r :
02 join t s r ep lac e m en t o f B1 0 NRI AC CE PT A BLE

For T C R AR AB IA In s p e ct ion Au th o ri ty Cl ie n t:
Nam e : R iz wan D e sa i N am e : Nam e :
Qu al if i cati on : M T l e ve l -I I De s ign ati on : De s ign ati on :
Si gn : Si gn : Si gn :
Dat e :1 9/ 1 0/ 20 09 Dat e : Dat e :
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page No.138/146

ULTRASONIC INSPECTION REPORT

Client: SWCC Jubail Report No. TCR/UT/01
Project : RLA - BOILER HT COMPONENT PH-1 U-5 Location: Saudi Arabia Date: 13/10/09
Test Procedure: TCR/QCP/UT/02 Rev.0 Reference: ASME SEC V Art.4 Acc. Std: ASME B31.1/ ASME SEC VII Div. 1
Material: CS Area Scanned: See Sketch Couplant: Cellulose Paste
Flaw Detector: Modsonic Model/ Sl. No.: E1814-1108 Surface Condition: Smooth
Examination System: Pulse Echo (A scan) Probe Type: Angle (0˚, 45˚, 70˚) Heat Treatment: Before After
Calibration Block: IIW-V2 & TCR/UT/BLOCK/02 Crystal Size: 10mmØ, (8 X 9) Defect Report Level: Above 20%
Reference dB: 34/62 dB Frequency: 4 MHz Defect Reject Level: Above DAC
Sensitivity
Scanning dB: Ref dB + 6 dB Description of Items : 323.9Ø X 33.32 t Drg No: PH1-MS-1-6-02

Location
SI. Length Depth Ref: Height
Item Description Weld Type Defect Type from Assessment
No. (mm) (mm) (+dB)
Datum
1 R 1 ( 01-JOINT) BUTT NSD ---- ---- ---- ---- ACCEPTABLE
2 B 1 ELBOW (01-JOINT) BUTT NSD ---- ---- ---- ---- ACCEPTABLE
3 B 2 ELBOW (01-JOINT) BUTT NSD ---- ---- ---- ---- ACCEPTABLE
4 V 1 VALVE (02-JOINTS) BUTT NSD ---- ---- ---- ---- ACCEPTABLE

Note: N.S.D – No Significant Discontinuity

TCR Interpreter (Level II) Reviewed By Client
Sign Sign Sign
Name Vishal Name Name
Date 13/10/09 Date Date
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page No.139/146

ULTRASONIC INSPECTION REPORT

Client: SWCC Jubail Report No. TCR/UT/02

Project : RLA - BOILER HT COMPONENT PH-1 U-5 Location: Saudi Arabia Date: 14/10/09
Test Procedure: TCR/QCP/UT/02 Rev.0 Reference: ASME SEC V Art.4 Acc. Std: ASME B31.1/ ASME SEC VII Div. 1
Material: CS Area Scanned: See Sketch Couplant: Cellulose Paste
Flaw Detector: Modsonic Model/ Sl. No.: E1814-1108 Surface Condition: Smooth
Examination System: Pulse Echo (A scan) Probe Type: Angle (0˚, 45˚, 70˚) Heat Treatment: Before After
Calibration Block: IIW-V2 & TCR/UT/BLOCK/02 Crystal Size: 10mmØ, (8 X 9) Defect Report Level: Above 20%
Reference dB: 34/62 dB Frequency: 4 MHz Defect Reject Level: Above DAC
Sensitivity
Scanning dB: Ref dB + 6 dB Description of Items : 323.9Ø X 33.32 t Drg No: PH1-MS-1-6-02

Location
SI. Length Depth Ref: Height
Item Description Weld Type Defect Type from Assessment
No. (mm) (mm) (+dB)
Datum
1 B3 ELBOW (02- JOINTS) BUTT NSD ---- ---- ---- ---- ACCEPTABLE
2 V2 VALVE (02- JOINTS) BUTT NSD ---- ---- ---- ---- ACCEPTABLE
3 B4 ELBOW (02- JOINTS) BUTT NSD ---- ---- ---- ---- ACCEPTABLE

Note: N.S.D – No Significant Discontinuity

TCR Interpreter (Level II) Reviewed By Client
Sign Sign Sign
Name Vishal Name Name
Date 14/10/09 Date Date
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page No.140/146

ULTRASONIC INSPECTION REPORT

Client: SWCC Jubail Report No. TCR/UT/03

Project : RLA - BOILER HT COMPONENT PH-1 U-5 Location: Saudi Arabia Date: 15/10/09
Test Procedure: TCR/QCP/UT/02 Rev.0 Reference: ASME SEC V Art.4 Acc. Std: ASME B31.1/ ASME SEC VII Div. 1
Material: CS Area Scanned: See Sketch Couplant: Cellulose Paste
Flaw Detector: Modsonic Model/ Sl. No.: E1814-1108 Surface Condition: Smooth
Examination System: Pulse Echo (A scan) Probe Type: Angle (0˚, 45˚, 70˚) Heat Treatment: Before After
Calibration Block: IIW-V2 & TCR/UT/BLOCK/02 Crystal Size: 10mmØ, (8 X 9) Defect Report Level: Above 20%
Reference dB: 34/62 dB Frequency: 4 MHz Defect Reject Level: Above DAC
Sensitivity
Scanning dB: Ref dB + 6 dB Description of Items : 323.9Ø X 33.32 t Drg No: PH1-MS-1-6-02

Location
SI. Length Depth Ref: Height
Item Description Weld Type Defect Type from Assessment
No. (mm) (mm) (+dB)
Datum
1 B5 ELBOW (02-JOINTS) BUTT NSD ---- ---- ---- ---- ACCEPTABLE
2 B6 ELBOW (02-JOINTS) BUTT NSD ---- ---- ---- ---- ACCEPTABLE
3 V4 VALVE (01-JOINT) BUTT NSD ---- ---- ---- ---- ACCEPTABLE
3 T 2 "T" JOINT (02 Nos) FILLET NSD ---- ---- ---- ---- ACCEPTABLE

Note: N.S.D – No Significant Discontinuity

TCR Interpreter (Level II) Reviewed By Client
Sign Sign Sign
Name Vishal Name Name
Date 15/10/09 Date Date
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page No.141/146

ULTRASONIC INSPECTION REPORT

Client: SWCC Jubail Report No. TCR/UT/04

Project : RLA - BOILER HT COMPONENT PH-1 U-5 Location: Saudi Arabia Date: 17/10/09
Test Procedure: TCR/QCP/UT/02 Rev.0 Reference: ASME SEC V Art.4 Acc. Std: ASME B31.1/ ASME SEC VII Div. 1
Material: CS Area Scanned: See Sketch Couplant: Cellulose Paste
Flaw Detector: Modsonic Model/ Sl. No.: E1814-1108 Surface Condition: Smooth
Examination System: Pulse Echo (A scan) Probe Type: Angle (0˚, 45˚, 70˚) Heat Treatment: Before After
Calibration Block: IIW-V2 & TCR/UT/BLOCK/02 Crystal Size: 10mmØ, (8 X 9) Defect Report Level: Above 20%
Reference dB: 34/62 dB Frequency: 4 MHz Defect Reject Level: Above DAC
Sensitivity
Scanning dB: Ref dB + 6 dB Description of Items : 323.9Ø X 25.4 t Drg No: PH1-MS-1-6-02

Location
SI. Length Depth Ref: Height
Item Description Weld Type Defect Type from Assessment
No. (mm) (mm) (+dB)
Datum
1 Y 1 "Y" JOINT (03-NOS) BUTT NSD ---- ---- ---- ---- ACCEPTABLE
2 B11 ELBOW (1 JOINT) BUTT NSD ---- ---- ---- ---- ACCEPTABLE
3 B12 ELBOW (1 JOINT) BUTT NSD ---- ---- ---- ---- ACCEPTABLE

Note: N.S.D – No Significant Discontinuity

TCR Interpreter (Level II) Reviewed By Client
Sign Sign Sign
Name Vishal Name Name
Date 17/10/09 Date Date
 Report No.: TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page No.142/146

ULTRASONIC INSPECTION REPORT

Client: SWCC Jubail Report No. TCR/UT/05

Project : RLA - BOILER HT COMPONENT PH-1 U-5 Location: Saudi Arabia Date: 18/10/09
Test Procedure: TCR/QCP/UT/02 Rev.0 Reference: ASME SEC V Art.4 Acc. Std: ASME B31.1/ ASME SEC VII Div. 1
Material: CS Area Scanned: See Sketch Couplant: Cellulose Paste
Flaw Detector: Modsonic Model/ Sl. No.: E1814-1108 Surface Condition: Smooth
Examination System: Pulse Echo (A scan) Probe Type: Angle (0˚, 45˚, 70˚) Heat Treatment: Before After
Calibration Block: IIW-V2 & TCR/UT/BLOCK/02 Crystal Size: 10mmØ, (8 X 9) Defect Report Level: Above 20%
Reference dB: 34/62 dB Frequency: 4 MHz Defect Reject Level: Above DAC
Sensitivity
Scanning dB: Ref dB + 6 dB Description of Items : 323.9Ø X 25.4 t Drg No: PH1-MS-1-6-02

Location
SI. Length Depth Ref: Height
Item Description Weld Type Defect Type from Assessment
No. (mm) (mm) (+dB)
Datum
1 C1 Reducer (02-Nos Joint) BUTT NSD ---- ---- ---- ---- ACCEPTABLE
2 HTSH Inlet Header - 02 Jts. BUTT NSD ---- ---- ---- ---- ACCEPTABLE
3 Lower Temp. Header - 03 Jts BUTT NSD ---- ---- ---- ---- ACCEPTABLE
Note: All the above Joints
are replacement of Hot
Area (B7,B8,B9,B10)

Note: N.S.D – No Significant Discontinuity

TCR Interpreter (Level II) Reviewed By Client
Sign Sign Sign
Name Vishal Name Name
Date 18/10/09 Date Date
 Report No.:TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page No.143 /146

ULTRASONIC THICKNESS MEASUREMENT OF

Main Steam Line Thickness, UNIT # 5
Nom. Thickness readings (mm)
Point No. Type
Thick (mm) A B C D
1 Reducer 33 33.4 34.3 33.2 34.4
2 Elbow 38 43.6 36.5 41.1 38.8
4 Elbow 38 37.6 38 39.8 37.8
5 Pipe 33 33.9 34.5 36.3 35.5
6 Pipe 33 33.7 34.5 35.5 35.5
7 Elbow 30 32.3 30.2 29.1 31.9
8 Pipe 25 26.5 25.2 26.1 27.4
9 Pipe 25 25.5 27.5 27.6 26.2
10 Pipe 25 26.7 28.1 26.9 25.3
11 Elbow 30 32 29 34.1 31.2
12 Elbow 30 30.8 34.6 31.8 32.4
13 Pipe 25 25.1 26.5 28 26.4
14 Elbow 30 31.9 32 35 30.6
15 Pipe 25 25.6 25.5 27.1 26.6
16 Elbow 30 36 32.7 32 31.1
17 Pipe 25 26.9 25.1 26.5 28
Pipe 25 28 27.9 26.6 27.1
18
Elbow 38 36 36.6 38 39.2
Pipe 25 27.6 25.8 25.8 27.6
19
T-Pice 45 52 51.9 51.9 52
Pipe 25 26 26.6 27.7 27.2
20
T-Pice 45 51.3 53 52.5 46.8
Pipe 25 27.8 27.3 26.9 26.9
21
Elbow 30 39 32.9 32 31.8
Pipe 25 26.1 26.6 27.8 28
22
Elbow 30 31.8 34 37.6 33.8
Elbow 30 28.8 31.9 32.5 37
23
Elbow 30 33.1 30.2 35 31.5
Pipe 25 27.4 27.4 27.5 28.6
24
Elbow 30 31 29.5 29.7 29.4
26 Elbow 30 32.8 29.7 29.5 27.8
27 Reducer(valve side) 45 42.8 42.4 44 42.2
28 Reducer(Drain Taping) 45 49.9 52.5 48.8 48.7
Pipe 25 27.1 27.9 26 26.2
29
Y-Pice 38 40.9 40.9 39.8 41.1
Pipe 20 19.4 21 21 19.8
30
Y-Pice 38 36.4 36.1 36 36.4
Pipe 20 20.1 20.1 20.9 20.7
31
Y-Pice 38 36 36.2 36.3 36.3
32 Pipe 20 19.7 19.5 20.8 21
33 Elbow 25 27.7 25 22.8 22.3
34 Pipe 20 20.1 19 20.3 21.1
35 Elbow 25 26.1 22.8 25.1 23
 Report No.:TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page No.144 /146

ULTRASONIC THICKNESS MEASUREMENT OF

LOW TEMPERATURE SUPER HEATER UNIT # 5
LOCATION - 1
Nominal Gauged Reading (mm) Nominal Gauged Reading(mm)
Tube no Thk % Loss Thk % Loss
(mm) Straight tube flame side (mm) Bottom of first U-Bend
1 4.0 4.13 - 4.0 4.42 -

2 4.0 4.37 - 4.0 4.41 -

3 4.0 4.31 - 4.0 4.45 -

4 4.0 4.28 - 4.0 4.33 -

5 4.0 4.45 - 4.0 4.22 -

6 4.0 4.38 - 4.0 4.32 -

7 4.0 4.71 - 4.0 4.34 -

8 4.0 4.98 - 4.0 4.34 -

9 4.0 4.37 - 4.0 4.47 -

10 4.0 4.51 - 4.0 4.43 -

11 4.0 4.43 - 4.0 4.31 -

12 4.0 4.32 - 4.0 4.46 -

13 4.0 4.37 - 4.0 4.38 -

14 4.0 4.49 - 4.0 4.3 -

15 4.0 4.54 - 4.0 4.37 -

16 4.0 4.55 - 4.0 4.48 -

17 4.0 4.53 - 4.0 4.46 -

18 4.0 4.45 - 4.0 4.37 -

19 4.0 4.46 - 4.0 4.43 -

20 4.0 4.51 - 4.0 4.55 -

21 4.0 4.42 - 4.0 4.42 -

22 4.0 4.63 - 4.0 4.43 -

 Report No.:TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page No.145 /146

THICKNESS MEASUREMENT OF
LOW TEMPERATURE SUPER HEATER UNIT # 5
LOCATION - 2
Gauged Reading Gauged Reading
Nominal Nominal
(mm) (mm) %
Tube no Thk % Loss Thk Loss
(mm) Straight tube flame Bottom of first U-
(mm)
side Bend
1 4.0 3.86 3.50% 4.0 4.02 -

2 4.0 3.92 2.00% 4.0 3.98 0.50%

3 4.0 3.98 0.50% 4.0 3.95 1.25%

4 4.0 3.89 2.75% 4.0 3.93 1.75%

5 4.0 3.94 1.50% 4.0 4 -

6 4.0 3.98 0.50% 4.0 3.92 2.00%

7 4.0 4.01 - 4.0 3.95 1.25%

8 4.0 4.07 - 4.0 3.87 3.25%

9 4.0 4.51 - 4.0 3.88 3.00%

10 4.0 3.87 3.25% 4.0 3.82 4.50%

11 4.0 3.96 1.00% 4.0 3.88 3.00%

12 4.0 3.97 0.75% 4.0 3.83 4.25%

13 4.0 4.09 - 4.0 3.91 2.25%

14 4.0 3.9 2.50% 4.0 3.89 2.75%

15 4.0 3.94 1.50% 4.0 4.06 -

16 4.0 3.9 2.50% 4.0 4.08 -

17 4.0 3.85 3.75% 4.0 3.87 3.25%

18 4.0 3.99 0.25% 4.0 3.95 1.25%

19 4.0 3.91 2.25% 4.0 3.92 2.00%

20 4.0 4.03 - 4.0 3.92 2.00%

21 4.0 4.09 - 4.0 3.98 0.50%

22 4.0 4.1 - 4.0 3.96 1.00%

 Report No.:TCR/002/10/RLA
TCR ARABIA COMPANY LIMITED
SALINE WATER CONVERSION CORPORATION Date: 01.02.2010
Report on RLA of Boiler Components, Phase I, Boiler # 5
Page No.146 /146

THICKNESS MEASUREMENT OF
LOW TEMPERATURE SUPER HEATER UNIT # 5
LOCATION - 3
Gauged Reading
Nominal Nominal Gauged Reading (mm)
(mm) % %
Tube no Thk
Loss
Thk Loss
(mm) Straight tube flame
(mm) Bottom of first U-Bend
side
1 4.0 5.3 - 4.0 5.03 -

2 4.0 4.85 - 4.0 5.1 -

3 4.0 4.78 - 4.0 5.07 -

4 4.0 4.81 - 4.0 5.42 -

5 4.0 4.78 - 4.0 5.97 -

6 4.0 4.83 - 4.0 5.13 -

7 4.0 4.97 - 4.0 5.56 -

8 4.0 4.94 - 4.0 5.17 -

9 4.0 4.82 - 4.0 4.78 -

10 4.0 4.92 - 4.0 5.04 -

11 4.0 4.98 - 4.0 5.19 -

12 4.0 4.73 - 4.0 5.2 -

13 4.0 4.96 - 4.0 5.15 -

14 4.0 4.67 - 4.0 5.29 -

15 4.0 4.68 - 4.0 4.97 -

16 4.0 4.73 - 4.0 5.44 -

17 4.0 4.79 - 4.0 5.03 -

18 4.0 4.73 - 4.0 4.91 -

19 4.0 4.82 - 4.0 5.03 -

20 4.0 4.51 - 4.0 5.13 -

21 4.0 4.82 - 4.0 4.91 -

22 4.0 4.8 - 4.0 5.17 -