Proven Plant Safety
Boilers suffer from aggressive forms of degradation that can lead to catastrophic wall failure and unplanned outages. Our boiler inspection process utilizes the advanced VertiScan™ system to rapidly evaluate water wall tubes during scheduled outages. By identifying critical defects before they cause a breach, we provide the data necessary to make proactive repair decisions and maintain operational continuity.
The VertiScan™ system is a game-changer for plant managers facing tight outage schedules. Unlike manual UT thickness gauging, our robotic TubeCAT™ crawler scans up to five tubes simultaneously at speeds of 5m (15′) per minute. The crawler can climb up to 100 feet and is designed to handle up to 6mm (1/4″) of scale on the tubes, ensuring a thorough inspection without the need for extensive surface preparation.
Once the scan is complete, results are presented immediately on a color-coded map. This visualization allows engineers to see exactly where hydrogen damage, ash erosion, or thermal fatigue is occurring. This high-speed approach ensures that the cost of an entire four-wall boiler inspection is significantly lower than the cost of a single emergency shutdown.
“Over these years, I was involved with the inspection of several boilers, using the latest RFT technology available, which keeps steadily improving. The current Ferroscope F308 multi-channel system and the latest software with array probe designs, built to suit the tube configuration, is in my opinion the best way to inspect the condition of most boiler tubes.”
Manager, Equipment Integrity, Acuren
“I first became acquainted with Remote Field Eddy Current technology in 1990 while employed with Hartford Steam Boiler Insurance Co. Through rigorous testing we determined that RFEC was the only suitable technology for the inspection of nested ferromagnetic boiler tubes. I have had a long business relationship with Dave Russell and his staff. They have always proved knowledgeable, responsive and more than fair in all of our dealings. I can highly recommend them to anyone.”
President, Boiler Inspection & Engineering, Inc.
“I confirm that ENEL has used RFT successfully for more than 10 years to test power station boilers and heat exchangers.”
Director, Tema Flux s.r.l.
Minimal preparation is required. Unlike manual UT, we only need basic access to the water wall; the robotic crawler handles up to 6mm (1/4”) of scale, significantly reducing your pre-inspection cleaning costs.
No. Because the TubeCAT™ crawler climbs up to 100 feet autonomously, you can eliminate the time and safety risks associated with building extensive scaffolding for manual inspections.
The map allows your maintenance crew to pinpoint the exact location and severity of thinning. You can finalize your repair or tube-replacement scope before the inspection team even leaves the site.
Yes. The VertiScan™ system is adaptable to various tube sizes and spacing. Contact our team to confirm the specific crawler configuration needed for your boiler’s geometry.
By comparing color maps from year to year, you can track degradation rates. This predictive approach helps justify future capital expenditures for partial or full retubing before a failure occurs.
Yes, we offer the system for sale, with training, to those customers world-wide who have their own inspection department.
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Don’t wait for a tube failure to force an emergency shutdown. Our boiler inspection experts are ready to help you plan a proactive maintenance strategy using the world’s most advanced robotic scanning technology. Contact Russell NDE today to discuss your next outage schedule.
