Strategy to increase the gap between OH of ST-I units

By Boiler Maint Dept

WATER WALL
LIMITING FACTORS Erosion at S panel. Steam erosion due to wall blower Fatigue failure at bottom end fins between panels Weld joint

Strategy for water wall

Present practices

Proposed Strategy

Tube rep after 20% erosion Soot blower operated from remote. There is no interlock for wall blower opn from steam temp. Wall blower is being operated 6 times a day. Radiography of all welded jts

Tube rep after 10% erosion Welding of sacrificial bar Soot blower operation from local. Incorporation of interlock for WB opn drain temp. Optimization and intelligent soot blowing Radiography of all welded jts

Radiant Super heater

LIMITING FACTORS Steam erosion due to wall blower Weld joint Mechanical rubbing of clamps. Blockage of tube during maint

Strategy for Radiant Super heater

Present practices

Tube rep after 20% erosion Soot blower operated from remote. There is no interlock for wall blower opn from steam temp. Wall blower is being operated 6 times a day. No gas cutting plastic capping Radiography of all jts

Proposed Strategy Tube rep after 10% erosion Soot blower operation from local. Incorporation of interlock for WB opn drain temp. Optimization and intelligent soot blowing Cutting by tube cutting m/c and using metal caps. Radiography of all jts

Platen Super heaters

LIMITING FACTORS Mechanical rubbing due to binders, connectors and shop joints. Weld joint Long term overheating Blockage of tube during maint

Strategy for Platen Super heater

Present practices

Proposed Strategy

Thorough inspection. Tube rep after 20% erosion. Insitu oxide scale measurement every alternate year No gas cutting plastic capping Radiography of all jts

Thorough inspection by team. Tube rep after 10% erosion Insitu oxide scale measurement every alternate year Replacement of tubes having higher oxide scale. Cutting by tube cutting m/c and using metal caps. Radiography of all jts Reinspection by team where ever maint work is done.

Reheaters-II & III

LIMITING FACTORS Mechanical rubbing due to T spacers. Weld joint Long term overheating Maint induced defect

Strategy for Reheater II &III

Present practice

Proposed Strategy

Thorough inspection. Tube rep after 20% erosion. Insitu oxide scale measurement every alternate year No gas cutting plastic capping Radiography of all jts

Thorough inspection by team. Tube rep after 10% erosion Insitu oxide scale measurement every alternate year Replacement of tubes having higher oxide scale. Cutting by tube cutting m/c and using metal caps. Radiography of all jts Reinspection by team where ever maint work is done.

Regulating Stage Reheater

LIMITING FACTORS Long term overheating. Random flue gas erosion. Constraint for inspection Weld joint Maint induced defect

Strategy for Regulating Stage Reheater

Present practice

Proposed Strategy

Thorough inspection of approachable area. Tube rep after 20% erosion. Insitu oxide scale measurement every alternate year No gas cutting plastic capping Radiography of all jts 3 way valve optimisation to control metal temp.

Thorough inspection of approachable by team. Tube rep after 10% erosion Insitu oxide scale measurement every alternate year Replacement of tubes having higher oxide scale. Cutting by tube cutting m/c and using metal caps. Radiography of all jts Reinspection by team where ever maint work is done. Monitoring metal temp and alarm provision in UCB.

Economiser
LIMITING FACTORS Constraint for inspection Flue gas erosion. Weld joint Maint induced defect

Strategy for Economiser

Present practice

Proposed Strategy

Thorough inspection of approachable area. Modular replacement Tube rep after 20% erosion. Inspection and repair of lower bank coils No gas cutting at vertical. plastic capping Radiography of all jts

Thorough inspection by team. Replacement of upper bank coils in every 6 years in phased manner. Inspection and repair of lower bank coils Cutting by tube cutting m/c and using metal caps. Radiography of all jts Reinspection by team where ever maint work is done.

Steam cooled wall & hanger tubes

LIMITING FACTORS Fatigue failure at bottom end fins between panels at second pass and goose neck side walls. Flue gas erosion. Weld joint Maint induced defect

Strategy for SCW & Hangers Present practice

Proposed Strategy

Thorough inspection of approachable area. Tube rep after 20% erosion. DPT of end fins between panels No gas cutting at vertical. plastic capping Radiography of all jts

Thorough inspection by team. Tube replacement after 10% erosion and shielding. DPT of end fins between panels Ensuring through ness of panel drains before unit shut down. Checking for free expansion of panels. Cutting by tube using tube cutting m/c and using metal caps. Radiography of all jts Reinspection by team where ever maint work is done.

vents and drains

LIMITING FACTORS Corrosion. Stub joint Weld joint Mechanical rubbing of lines at pent house entry. Maint induced defect

Strategy for Vents and drains

Present practice

Proposed Strategy

Thorough inspection after removal of insulation. DPT of stubs. Radiography of all jts

Thorough inspection after removal of insulation for corrosion and mechanical rubbing. Replacement of all vents and drains after one lakh running hours. Replacement of corroded tubes. DPT of stubs. Radiography of all jts Reinspection by team where ever maint work is done.

Pent house
LIMITING FACTORS Mechanical rubbing Stub joint. Weld joint Spray line stubs Maint induced defect

Strategy for Pent house

Present practice

Proposed Strategy

Thorough inspection by team. DPT of stubs. Radiography of all jts

Thorough inspection for corrosion and mechanical rubbing of lines. DPT of stubs. Inspection adjustment o hangers. Replacement of all vents and drains after one lakh running hours. Replacement of corroded tubes. DPT of stubs. Radiography of all jts Reinspection by team where ever maint work is done.

Coal burners
LIMITING FACTORS Minor erosion of coal nozzle

Erosion in coal nozzle tips is minimum. Coal nozzle area of erosion can be strengthened life can be extended.

Milling system
LIMITING FACTORS More than 50 percent bends are MS fabricated. Coal pipe orifice. MDVs, MPOs RCfeeder chute Mill inner cone

Strategy for Milling system

Present practice Replacement of eroded coal pipe bends (35-40 nos) every year Replacement of50 percent MPOs. Replacement of30 percent MDVs Replacement of30 percent MDVs Replacement all orifices

Proposed Strategy Provision electrical operated gate at burner inlet to isolate milling system. Replacement of all MS bends with ceramic lined bends

Airpreheaters
LIMITING FACTORS CE baskets lattice and their support. APH support bearing

Strategy for Airpreheaters

Present practice

Proposed Strategy

Replacement of eroded lattice. Replacement of eroded lattice supports. Wear debris analysis of APH bearing and gear box lub oil once in 3 months

Replacement of all lattice Replacement of all lattice supports Withdrawal and inspection of APH support bearing during capital OH. Wear debris analysis of APH bearing and gear box lub oil once in 3 months

Conclusion
Following action can increase OH Gap

Replacing eroded tubes below 10%. Extensive DPT as identified locations. Replacement of ECO upper bank coils once in six years. Optimization and careful operation of wall blowers. Insitu oxide scale measurement once in two years and replacing higher oxide scale tubes. Installation of gate for isolating milling system near burner.

Conclusion

Educating the maintenance contract personnel about possible maintenance induced defect. Radiography of all welded joints. Replacing vents and drains periodically. Heating and cooling boiler in normal way. Wear debris analysis of APH lub oil. Withdrawal of APH bearing for inspection during capital OH.