Documente Academic
Documente Profesional
Documente Cultură
12.03.2010
P > 1 Kg / cm2
Economizer
Super
Heaters
Re-Heaters
Water Walls
Safety valves
De-Super heaters and
Boiler Drum
TO PREHEAT FEEDWATER
TO RECOVER HEAT FROM FG LEAVING BOILER
Finned staggered
Bare tube inline
CARBON STEEL
FUNCTION:
It increases the temperature of Main
steam with the help of temperature of
flue gases to get Saturated Steam
admitted to the HPT.
FUNCTION:
It heats the temperature of steam outlet
from HPT with the help of Flue gas
temperature.
FUNCTION:
Water walls carry feed water from ring
headers to Boiler Drum through raiser
tubes.
Increase in efficiency.
Better heat transfer.
Easy and quick erection.
Increased availability of Boiler.
FUNCTION
These are used to safe guard the equipment
in case of emergencies.
FUNCTION:
It controls the main steam temperatures to
safe limit.
FUNCTION:
Max. Temp. C
(Oxidation Limit)
ASTM
SA 210 Gr. A1
425
SA 209
T1
480
SA 213
T11
% Mo steel C 0.10to
0.20%Mn
0.30to0.80%P0.025Si0.025
s
1 % Cr. % Mo
SA 213
T22
2 % Cr. 1 % Mo
580
SA 213
TP 304 H
18 % Cr. 8 % Ni
(Stainless steel)
700
SA 213
TP 347 H
18 % Cr. 10 % Ni
700
550
By
Very
high expectations on
performance
Fuel quality deterioration
New / imported fuels coming to
use
Cheaper power to public Govt
Availability based tariff
Achieving
higher availability
Optimal performance of the
units
Ability to vary load & meet
varying targets
Optimizing combustion for
varying fuel characteristic
Better
power
Lower pollution levels
Better position in ABT
Low gestation period
Enhancing
Better
power
Lower pollution levels
Better position in ABT
Low gestation period
Enhancing
Making
rate
Handling the fuel quality change
Operational deviations
Reducing the damage
mechanisms
Stress Rupture
Short Term Overheating
High Temperature Creep
Dissimilar Metal Welds
Water-side Corrosion
Caustic Corrosion
Hydrogen Damage
Pitting
Stress Corrosion Cracking
Fire-side Corrosion
Low Temperature
Waterwall Coal Ash Oil Ash
Fatigue
Vibration
Thermal
Corrosion
Erosion
Fly Ash
Falling Slag
Soot Blower
Coal Particle
Steam / Water
cooled tubes
Plugged by debris,
scale etc.
High Heat
Transfer /
Improper firing
Low water/steam
flow due to poor
circulation /
upstream leak
Corrective Action
Prevent Blockage
Maintain Drum
level
Assure Coolant
flow
Reduce over firing
Redesign tubing
to promote flow
Relocation of
horiz. / inclined
tubes to avoid
film boiling
Typical Locations
Steam cooled
Tubes
Partially choked
Radiant Heat Zone
Gas Blockage
Incorrect Material
Material Transition
Higher stress due
to
weld attachment
Corrective Action
RLA/
IOT
Fluid flushing
Material upgrades
Typical Locations
Corrective Action
At SH / RH dissimilar
weld joints :
Temperature / Stress
excursions
Repair/Replacement
Relocating the weld
Use of Ni-base filler
Frequent inspection
Mechanism : 1. The formation of carbon depleted zone on the ferritic side of the
transition from the ferritic to austenitic structure is the initial step and any
treatment which enhances the formation of this zone will enhance the failure
probability.
2. The carbon depleted soft feerritic zone is constrained by the sorrounding harder
and stronger material and is subjected to strains induced by thermal expansion
mismatch, bending, vibration and pressure.
3. The strain accumulation in the carbon-depleted zone is relieved by creep at
elevated temperature.
4. Creep damage in the form of cavitation, grain boundary sliding and tearing
results in cracking in the carbon depleted zone along and adjacent to the weld
interface
Typical Locations
Corrective Action
Water-cooled Tubes:
At flow disruptions
Horiz / inclined tube
High Heat flux zone
Flame impingement zone
Typical Locations
Water-cooled Tubes:
At flow disruptions
Horiz / inclined tube
High Heat flux zone
Flame impingement zone
Corrective Action
Typical Locations
attachment welds
Probable Root
Cause
Corrective Action
Replacement
Surveillance for
carry-over
Heat Treatment of
bends
Care during chemical
cleaning
Use of 347H tube
Typical Locations
Corrective Action
Changing operating
conditions like reduced
load, low excess air etc.
Protections like shields,
baffles etc.
Flow Model study
Design stage:
Selection of material,
Manufacturing aspects
Transportation / Handling
Storage
Erection
Commissioning
Operation and Maintenance
SB STEAM EROSION
Ensure condensate free steam with a minimum
superheat of 15 C at blower.
Necessary gradient/downward slope of the SB piping
is to be ensured. 1 per meter length of pipe is to be
maintained.
Through thickness survey of WW in the SB location for
three meter radius and replacing the eroded tubes.
Ensuring wall blower nozzle alignment.
Temporary shielding / spraying.
Installing thermal drain system if not available.
Check
>
HYDROGEN EMBRITTLEMENT
WATER SIDE CORROSION / CAUSTIC GOUGING.
Maintaining / monitoring the water chemistry
guidelines.
Avoiding corrosion products ingress.
Controlling copper deposition thro condenser
leakage.
Chemical cleaning of the boier whenever deposit
quantity is > 40 mg /cm2
Carrying out the in-situ hydrogen embrittlement
survey.
Replacing the affected tubes
INTERNAL / O2 PITTING
Ensuring proper operation of de-aerator.
Control feed water oxygen levels to <10 ppb at
CEP out let.
Preservation of the boiler during short /long
outages by dry / wet preservation methods.
FRETTING / RUBBING.
Ensuring
FATIGUE
WELDING DEFECTS
Ensuring the qualified welder.
Adopting proper quality control procedures.
Process controls.
Replacement of defective joints.
Preventive actions.
Thank You