Why Select UDC For

Boiler Inspections?
United Dynamics Corporation’s Personnel - Raising the Standard Across the Industry
The UDC Difference
At UDC, our core business is boiler inspection and as with any service based
business, both company name and reputation are defined solely by our staff’s
experience, talent, and quality. This is the heartbeat of UDC since inception
some 30 years ago and today remains our business model.

All UDC Field Service Inspectors are full-time salaried employees. It is with strong
conviction we understand the retention of inspectors is a key component for
success. The distinction of employee retention which is paramount at UDC
enables us to sustain and maintain our experienced and highly specialized staff.

No temporary help, general NDE representatives, or inexperienced boiler

personnel are ever utilized for any inspection. If our schedule is completely
booked and we are unable to staff an inspection project with our certified and
experienced personnel, the work will be declined in order for us to consistently
offer our clients nothing less than the highest quality inspection service solutions.

On average, a UDC field services inspector spends 180 to 200 days per year
performing inspection work for client overhauls. Inspectors provide services
on 15 to 35 outages annually encompassing a variety of different work scopes,
timelines, and boiler designs.

During non-field work time periods, UDC mandates a vigorous training program
on multiple platforms for all inspectors. Continuous education and training serves
as a key resource for developing our specialized staff. UDC has established a
requirement of boiler inspection training which consists of three levels of
certification. Our inspectors hold certification through the established
association which sets the industry standard criteria for qualification of
best inspection practices.

Safety is priority one at UDC and is treated as such; every inspector operates by
this standard. Simply stated, our safety record is impeccable. Each inspector is
OSHA-30 hour trained and compliant. As dictated by procedure, all UDC field
service representatives partake in annual respirator fit tests, annual physical
examination including pulmonary testing, and a bi-annual and/or random
substance abuse testing practice.

When you choose UDC, you continually receive repeatable quality, consistency,
and uncompromised levels of experience. We ensure that the same project
team leader (lead man) returns to each and every overhaul accompanied and
supported with a qualified and experienced team of inspectors. This promotes
consistent, accurate, and efficient inspections and builds a strong and trusted
working relationship between plant personnel and UDC staff.

Never compromise…..experience the UDC difference!

UDC...Serving the Power Industry since 1979!

 2681 Coral Ridge Rd
United Dynamics AT Corporation Brooks, KY 40109
Serving the Power Industry Since 1979 (502) 957-7525 Tel

United Dynamics Corporation stands firmly behind

our recommendations and services. Our priority is
quality job performance and customer satisfaction.

COMPANY OBJECTIVES

Optimization of Boiler Safety

Improve Boiler Availability

Minimize Financial and Generation Loss

Promote Pro-
Pro-Active Maintenance Solutions

NDE SERVICES
FIVE CORE VALUES
Oxide Thickness Testing
Experience Phased Array Ultrasonic Testing
Ultrasonic Testing
Consistency Magnetic-Particle Testing
Dye-Penetrant Testing
Knowledge Header Replications

Certified Weld Inspections

Schedule

Visual Inspections of Auxiliaries

Real Time Reports

Material Condition Assessments

INSPECTION SERVICES Remaining Life Assessments

VISUAL INSPECTIONS

Utility Fossil-Fired Boilers OTHER SERVICES

Heat Recovery Steam Generators Outage Management
Black Liquor Recovery Boilers
Waste-to-Energy (Refuse) Boilers Component Replacement Management

EDUCATIONAL TRAINING SEMINARS

Boiler Inspection Techniques Level I
Boiler Inspection Techniques Level II
HRSG Inspection Techniques
Joint Approach to Boiler Tube Failure Prevention
Operators Impact on Boiler Tube Failures
Boiler Inspection Outage Management and Planning

Experience the Difference with POWERFUL Results...

 2681 Coral Ridge Rd
United Dynamics AT Corporation Brooks, KY 40109
Serving the Power Industry Since 1979 (502) 957-7525 Tel
(502) 957-5441 Fax

Inspection services are UDC's core business.

All repair recommendations through our inspection program are

unbiased; based on sound engineering judgment, experience,
and quantitative data for justification purposes. An understanding
and regard for current plant economic environment is considered
in the evaluation process for every repair recommendation.

UDC services a variety of makes (B&W, CE, FW, Riley Stoker),

vintages, sizes (20mw to 1300mw), and designs of boilers. Fossil
fuel, waste to energy, and HRSG units are our specialty. Annually
UDC performs 80 to 100 boiler inspections on average within the
continental US and Hawaii. Our portfolio also includes work per-
formed internationally in Australia, Canada, China, the Dominican
Republic, Korea, Trinidad, and the Virgin Islands.

Our Five Core Values

Experience
UDC field service boiler inspection representatives are more experienced. Each representative at UDC is exposed to 25+ out-
ages per year possessing 5 to 10+ years of field service experience.
Consistency
The same UDC boiler inspection representatives return to your outages. This promotes consistent, accurate, and efficient boiler
inspections and builds a strong relationship between plant personnel and UDC staff.
Knowledge
UDC services literally hundreds of boilers including a variety of makes, vintages,
sizes, and designs. With this exposure, a continuous learning atmosphere is created
and a wealth of knowledge is developed by each and every service representative
from repair methodology to the latest inspection procedures and technologies.
Schedule
UDC can conduct a full-scope boiler inspection in a short period of time utilizing a
large and experienced inspection team. UDC routinely accommodates this type of
boiler inspection project for many customers promoting the maximization of plant
maintenance resources and budget.
Real Time Reports
Throughout the duration of the outage, reports are issued after each component of
the boiler is inspected. This creates an environment which limits downtime for skilled
laborers and allows you (the client) sufficient time to review, verify/ order materials,
and designate which repairs will be addressed during the overhaul.

▪ Phased Array Ultrasonic Testing ▪ Dye Penetrant Testing

▪ Metallurgical Replications ▪ Magnetic Particle Testing

▪ Ultrasonic Testing ▪ Oxide Thickness Testing

UDC utilizes a variety of basic and special method non-destructive

examination (NDE) techniques to determine material integrity and
to perform condition assessments of various boiler components as
well as auxiliary boiler equipment.

All Field Services Representatives receive NDE training and are tested
and certified through UDC NDE procedures which are written in accor-
dance with Recommended Practice No. ASNT SNT-TC-1A and ANSI/
ASNT CP-189.
 2681 Coral Ridge Rd
United Dynamics AT Corporation Brooks, KY 40109
Serving the Power Industry Since 1979 (502) 957-7525 Tel
(502) 957-5441 Fax

UDC’s professional field services enable our clients to improve unit availability and also
streamline scheduled maintenance overhauls. We provide complete documentation
as well as an available continuous database of yearly maintenance activities. Over
thirty-eight years of in-the-field experience underpins UDC with the knowledge and
tools required to assist our clients in preserving time & revenue in their current boiler
maintenance and improvement programs.
KEY FEATURES
▪ Turnkey planning and management of boiler maintenance outages
▪ Complete and thorough boiler and auxiliary equipment inspections
▪ Budgeting, Scheduling, and Planning
▪ Deployment and utilization of highly skilled inspection personnel
▪ Daily interface and documentation for management and contractors
▪ Follow-up of all reported work including current status reports
▪ Management and coordination of all NDT testing (UT, MT, PT, RT, Replications, etc.)
▪ Assessment and documentation of Corrosion / Erosion Rates and/or change in life
assessment
▪ Materials Management
▪ Current and future outage recommendations

UDC creates exact scaled component drawing replications from original component design specifications and drawings in
digital format through the use of CAD technology. The drawings produced ensure an “easy to read and interpret” format.
Update services are also available for any drawing produced by UDC to accommodate design changes to existing compo-
nents or component replacements.

Key Features
▪ Scaled graphic boiler component and side view drawings
▪ Detailed material depiction by specs (Material x OD x MWT) and assigned color coding
▪ Field weld lines and DMW lines are illustrated
▪ Assembly and tube counts are illustrated
▪ Elevations are illustrated
▪ Detail of soot blowers, observation and test ports, access doors, and adjacent components are depicted
▪ Layering feature allows any material to be viewed separately from the complete component drawing
▪ Drawings can be modified to include part or commodity numbers

UDC maintains a staff of Certified Weld Inspectors to accommodate any size work scope.

TYPICAL CWI TASKS

▪ Inspection of welds for conformity and deficiencies (i.e. porosity, excessive penetration, etc.)
▪ Verification of base materials and consumable welding materials in conformance to the specifications including the welding
filler metals used for each base material or combination of base materials are as specified
▪ Verification of the welding equipment to be used for the work as to appropriateness for use with the welding procedure
▪ Verification of the welding procedures as specified and the qualification of the procedure, including that the welding
performed is in conformance to applicable procedure
▪ Witness performance and testing of procedure qualification test assemblies
▪ Verification of welders, welding operators, and tack welders in regard to qualifications in conformance to the applicable
standards, and qualifications to use the welding procedures specified for the work
▪ Witness and/or supervise administration of the welder test assemblies and require re-qualification for welder's whose work
does not conform to applicable standards
 2681 Coral Ridge Rd
United Dynamics AT Corporation Brooks, KY 40109
Serving the Power Industry Since 1979 (502) 957-7525 Tel
(502) 957-5441 Fax

The need for advanced education and training in the area of boiler inspection techniques and methodology continues to be apparent given
increased regulations, equipment exceeding expected life, sophisticated technology, new testing procedures, new repair philosophy, com-
pany downsizing, and industry’s aging workforce. Given the variables, UDC created educational seminars designed to cater to these needs
and provide excellence and expertise in education and training for those who function in all capacities within the industry. Annually, UDC
trains some 600 individuals in the disciplines of Boiler Inspections. Each course offered by UDC is conducted at various locations sponsored
by UDC (public seminars) or a location of your choice (private in-house/in-plant seminars).
Boiler Inspection Techniques Seminar—
Seminar—Level I
Our Boiler Inspection Techniques Level I provides a comprehensive overview of boiler history and basic as well as advanced concepts
pertaining to overall inspection procedures, failure mechanisms, component and boiler fundamentals, NDT practices, welding procedures,
outage preparation, and use of steel and refractory materials. The seminar provides all necessary information to establish and implement
an in-house inspection team, clarify appropriate repair procedures, reinforce an existing in-house inspection team, or as a tool to further
personnel knowledge. This seminar is an excellent educational experience for new and experienced personnel alike.
Boiler Inspection Techniques Seminar—
Seminar—Level II
Boiler Inspection Techniques Level II is designed for plant personnel who previously possess some boiler inspection knowledge. The
seminar provides a comprehensive presentation of advanced concepts of inspection procedures, failure mechanisms, component and boiler
fundamentals, NDT practices, welding procedures, outage preparation, the use of steel and refractory materials, and introduces basic
metallurgical concepts. The seminar provides the veteran inspector with greater knowledge of inspection techniques and applications, tools
to establish and implement an in-house inspection team, clarify appropriate repair procedures, reinforce an existing in-house inspection
team, or as a tool for furthering personnel knowledge. This seminar is an excellent educational experience for all levels of plant personnel
involved with plant maintenance programs and efficiency.
Operator Impact on Boiler Tube Failure
Operators Impact on Boiler Tube Failure maps a course through cycling of the boiler viewing ramp rates, the failures which stem from
cycling the boiler, and operational upsets and the failures resulting from these upsets. Boiler water chemistry and its importance including
the failures arising from water chemistry problems are included in the informative discussions. Boiler offline procedures, fill requirements,
and applications of steel materials are among the topics covered in the seminar. This seminar raises awareness of the overall impact of
operations with techniques and tools to prevent failures from an operational standpoint.
Boiler Outage Management and Maintenance
Boiler Outage Management and Maintenance is designed for plant or corporate personnel involved with coordinating and managing the
inspection outage. The overall success of availability and reliability is dependent on the overall success of organization and recorded
compilation of data discovered through inspection and the strategic process of coordinated repair criteria list produced through the outage
management team. The seminar will provide tools and procedures which enables the management of inspection outrage utilize the overall
process for the most productive results possible.
A Joint Approach to Boiler Tube Failure Prevention
A Joint Approach to Boiler Tube Failure Prevention is an insightful presentation examining the positive results of identification of existing
conditions within the boiler for prevention of tube failure. The combined efforts of “in-the-field” inspection and laboratory analysis of sam-
pling tubes or failed boiler tubes provides strategic data for implementing strategic failure preventive maintenance solutions. Some of the
topics include cycling the boiler, operational upsets and resulting damage, quench cracking from water lances/cannons and the strategies
for approaching these problems. Discussion of the importance of a good water chemistry program, acid phosphate corrosion, caustic corro-
sion/gouging, copper deposition, and hydrogen damage, as well as pitting, scale and water side contaminants are part of the presentation.
This seminar is a must for maintenance personnel as well as operators and plant managers.
HRSG Inspection Techniques
HRSG Inspection Techniques is designed to provide a fundamentals overview and inspection techniques of the combined cycle plant. This
includes planning and documentation for advanced online and offline inspections covering external inspection, gas side inspection, water
side inspection, and fire side inspection. The gas side topic will look at gas exposed components such as drums and headers, superheaters,
reheaters, desuperheaters, evaporators, economizers, and pre-heaters. Water side and fire side tube failure prevention methods as well as
many case histories are included along with physical samples for the topics covered during the sessions.
 2681 Coral Ridge Rd
United Dynamics AT Corporation Brooks, KY 40109
Serving the Power Industry Since 1979 (502) 957-7525 Tel
(502) 957-5441 Fax

Gtrack v 3.5.3

Inspection Report Created on 4/26/2010 @ 1:30 PM Page 2 of 10

Station: Any Station / Unit #: 1 Report Name: 1-Extended Side Waterwalls

=================================================================================
P R I O R I T Y # 1 R E P A I R S
=================================================================================

Action: TUBE REPLACEMENT-P1

Priority #: 1
Inspector: Smith J

General location is Left Extended Side Waterwall, At Up-

per Arch Intersection

Elevation: 6074'

Cause: Erosion (Fly Ash/ Soot Blower)

Appearance: Localized Wall Loss

Tube Material: 2.5" OD x 0.240" MWT x SA-210A1

IK/IR Path: #6

Replace the following left extended sidewall tubes due to remaining wall thicknesses (RWT) at or below
65% of MWT:

Tube# (RWT) Inspection

T8 (0.108")
T9
T10
(0.080")
(0.138")
Report
T11
T12
(0.143")
(0.135") Sample

Upper cut line will be a minimum of 1' up from the floor intersection; lower
cut line will be made from the upper dead air space where feasible given the
bifurcate arrangement. Fly ash and soot blower erosion are the contributing
factors causing tube degradation.

Due to the difficulty associated with tube replacement in this area (i.e. lack
of scaffold for adequate access from upper dead air space, removal of external
lagging and insulation, demo & re-installation of sidewall seal, lead-time on
bifurcate tube sections from supplier, limited time remaining during outage for
repairs, etc), alternative repair methods can be employed such as weld restora-
tion (pad welding) until tube replacement is feasible.

Ensure that thinned walled welding procedures are employed to include the use of TIG welding if this
alternative repair method is chosen. If replacement is the chosen method of repair, adjacent tubes
which are eroded and below MWT should be replaced at this time (as detailed on page 3 of this report).
Consider the application of weld overlay on new tubing to provide additional erosion resistance.

Work Order: _____________ Status: Inspected

ã 1995-2010 UDC 502 957 7525

 2681 Coral Ridge Rd
United Dynamics AT Corporation Brooks, KY 40109
Serving the Power Industry Since 1979 (502) 957-7525 Tel
(502) 957-5441 Fax

Department
Department Name
Name Phone
Phone- -Extension
Extension Email
Email
Vice
VicePresident
PresidentField
FieldServices
ServicesDivision Jason
Division JasonC.C.Shankle
Shankle 502.957-7525
502.957-7525x2207
x2207 jshankle@udc.net
jshankle@udc.net
Manager
ManagerSales,
Sales,Marketing,
Marketing,Education
Education Sherri
SherriL.L.Hart
Hart 502.957-7525
502.957-7525x2222
x2222 shart@udc.net
shart@udc.net
Manager
ManagerInformation
InformationTechnology
Technology Clark
ClarkVan
VanKampen
Kampen 502.957-7525
502.957-7525x2208
x2208 cvankampen@udc.net
cvankampen@udc.net
Manager
ManagerNDE
NDEField
FieldServices
Services Michael
MichaelPannell
Pannell 502.957-7525
502.957-7525x2223
x2223 mpannell@udc.net
mpannell@udc.net
Manager
ManagerHRSG
HRSGField
FieldServices
Services Robert
RobertM.
M.Bevilacqua
Bevilacqua 502.957-7525
502.957-7525x2206
x2206 rbevilacqua@udc.net
rbevilacqua@udc.net

United
United Dynamics
Dynamics “Advanced
“Advanced Technologies”
Technologies” Corporation
Corporation

2681 Coral Ridge Rd.

Brooks, KY 40109
Tel: 502.957.7525
Fax: 502.957.5441
Email: sales@udc.net
www.udc.net