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NTPC Limited

WELCOME TO THE PRESENTATION


PRESSURE PARTS FAILURE REPORTING, INVESTIGATION & ANALYSIS SYSTEM & BOILER TUBE FAILURE MANAGEMENT THROUGH QUALITY UNIT OVERHAULS

By Anil Kumar AGM (Mech) PIE 7th August 2007-UPRVUNL: Panki

PRESSURE PARTS FAILURE REPORTING, INVESTIGATION, ANALYSIS & DATA SYSTEM


OBJECTIVE:
TO ACHIEVE ZERO TUBE LEAKAGE BASED. BTF ACCOUNTS FOR 60-80% OF TOTAL DOWN TIME

SCOPE:
PRESSURE PARTS FAILURE REPORTING, INVESTIGATION, ANALYSIS & DATA SYSTEM AIMS TO ACHIEVE ZERO BTL BASED ON RCA & TIME BOUND CORRECTIVE ACTION PLAN IT DEFINES RESPONSBILITIES OF VARIOUS GROUPS WITHIN THE ORGANIZATION & COORDINATION WITH EXTERNAL AGENCIES TO CARRY OUT DT/NDT INSPECTIONS, INVESTIGATION & ANALYSIS, FEEDBACK & DOCUMENTATION AND ACTION PLAN TO ACHIEVE THE OBJECTIVE BASED ON GENERATED DATA BASE

BOILER TUBE FAILURE MANAGEMENT

1. BTL Reporting Format 2. BTL Site Level Investigation Committee : Sampling Methodology: Two photographs 100x150 mm : One in situ, if possible & another after cut Identification plate 300x200 mm painted black with information containing Name of the station, unit no, location 7 details of failure, Date of Failure, Id. No etc Tube shall be cut by saw with 18 either side of failure. If gas cut it must be 24 either side & dressed to 18 by saw later Site Level Investigation: Observations, Analysis, Recommendations & Implementation Plan

BOILER TUBE FAILURE MANAGEMENT

3. Reporting at HQ- Operation Services for Further Action 4. Need of Metallurgical Investigation at R&D Lab 5. Documentation, Report Integration & Corrective Action Plan 6. Knowledge Forum for New Technological Adoption 7. Pre-OH predictive scope of work & preparedness 8. Quality Surveillances during unit overhauls (in-house/HQ/External Agency directly under FQA)

BOILER TUBE FAILURE REPORTING FORMAT

BOILER TUBE FAILURE REPORTING FORMAT

BOILER TUBE FAILURE SITE LEVEL INVESTIGATION COMMITTE 1. HOD - Maintenance Management Services: Coordinator 2. HOD- Boiler Maintenance Division 3. HOD- Operations & Energy Efficiency Division 4. HOD- Operations Division

BTF INVESTIGATION PROCESS


Site BTF Committee (Maint. Planning, BMD, Operation, O&EE) [REPORT-within 72 Hrs of completion of repairs] 1. 2. 3. Format: Photographs: Sample :
Duly filled with all relevant details Specifying station/unit no/date of failure Tube must be saw cut 18 either side of failure

HQ-OS

BTF

R&D Investigations (if required) Observations Corrective Action Plan Monitoring of CAP
QC: External Inspections & NDT

Unit OH Plan
Scope of Work for Unit Overhauls

New Technology Interventions

BOILER TUBE FAILURE MANAGEMENT

PREVENTION ASPECTS

BTF REDUCTION STRATEGY

OPERATION ASPECTS MAINTENANCE ASPECTS DESIGN ASPECTS

BOILER TUBE FAILURE MANAGEMENT

OPERATIONAL ASPECTS
LOW PARAMETER OPERATION OF BOILER PRESSURE PARTS (AT LOW PRESSURE & LOW TEMPERATURE) DOES NOT NECESSARIALLY ENSURE LESS PRESSURE PART FAILURES
IMPACT ANALYSIS OF PP-OPERATIONAL REGIME RESTRICTIONS at one of the NTPC-PIE Stations
D-3: Restricted to 95-100 kg/cm2 from design 149 kg/cm2 D-4:Restricted to 120 kg/cm2 from design 149 kg/cm2

UNIT NO

Before (April-Aug 06) Duration= 5 Months Nos MU Lost 63.73 72.79 BTF/M 1.6 0.8 8 4

After (Sept 06-March 07) Duration= 7 Months Nos 10 2 MU Lost 92.42 21.65 BTF/M 1.4 0.3

D-3 D-4

BOILER TUBE FAILURE MANAGEMENT

OPERATIONAL ASPECTS
1. NEED OF STANDARD & MANAGEMENT APPROVED OPERATIONAL PRACTICES 2. KNOWLEDGE MANAGEMENT: Forum for discussion &
deliberations

3. FOCUS ON WATER CHEMISTRY: Strategic control of


Boiler water & steam purity to keep boiler tubes interior clean for effective heat transfer need to be given top most priority

4. MONITOR TEMPERATURE EXCURSIONS: Discuss 5. Ensure availability of all P&I and auto loops/logics.
Avoid drum level surge

during daily review meeting for larger awareness & better control as a good operational practice.

BOILER TUBE FAILURE MANAGEMENT

OPERATIONAL ASPECTS
5. ENSURE ADEQUATE/PROPER SOOT BLOWING: Soot Blower operation optimization to prevent erosion due to excessive soot blowing, high steam pressure or pitting due to low /wet steam parameters is essential. There is need to optimize parameter regime as well as frequency of soot blower operation 6. CPU IN SERVICE: to remove all cruds from condensate, to reduce water wall internal deposits 7. CLEAN APH BASKETS: to ensure smooth flue gas flow & reduce second pass deposit & high temperature.

BOILER TUBE FAILURE MANAGEMENT

OPERATIONAL ASPECTS
08. COMBUSTION OPTIMIZATION: to reduce slagging & clinker fall, to prevent fin weld fouling, to reduce the need to soot blow, to ensure smooth flue gas velocity, to prevent thermal shocks & vibrations to pressure parts, to prevent implosions/explosions etc combustion optimization is essential. Excess air/ Air ingress control Flue gas temperature optimization 09. TRIP MANAGEMENT: dedicated group for honest trip analysis. Avoid trips

BOILER TUBE FAILURE MANAGEMENT

OPERATIONAL ASPECTS
Ownership role of Operations Training & Skill dominant career growth plan

Single point responsibility with HoD (Operation) for


House Keeping & Routine equipment/ panel cleanliness. Good illumination to ensure safe & efficient work conditions
Adequate attention & full preparedness in Fire Fighting Systems wrt fire related eventualities. Water Management to ensure adequate availability of water for CW system/Emergency services etc. Ash Dyke Management to ensure trouble free ash evacuation without affecting generation

BOILER TUBE FAILURE MANAGEMENT MAINTENACE ASPECTS

ORGANIZED & QUALITY UNIT OVERHAULS WITH FULL PREPAREDNESS

BOILER TUBE FAILURE MANAGEMENT MAINTENACE ASPECTS


1. 2. BTL ANALYSIS & TRENDING OF FAILURE PATTERN BOILER CONDITION ASSESMENT DURING EVERY OVERHAUL BY THIRD PARTY & DOCUMENTATION Erosion Survey Tube Condition Assessment for Deposits & need for acid cleaning etc. Inspection of Hangers & Supports, Expansion Guides etc GOOD PLANNING OF UNIT OVERHAULS Adequate Scope of Work Advance Resource Planning wrt Spares, Skill (Quality & Quantity), T&P Boiler OH only with full preparedness wrt spares, material & contracts Use of Maintenance Quality Checks & Protocol (M-QCP) Sheets Third party inspection, NDT & Radiography under Station Quality Control.

3.

BOILER TUBE FAILURE MANAGEMENT MAINTENACE ASPECTS


3. GOOD PLANNING OF UNIT OVERHAULS (Contd.) Use of independent inspection/survey/NDT agency under boiler maintenance engineer for erosion survey & radiography etc. 80% -100% radiography of joints. Tube thickness survey at right locations. Inspection of tubes after fin cutting and DPT of Fin welding & old joints/supports/stub/ attachment etc. Radiography of old welding joints, IPW & DMW joints. Radiography of bends to detect internal chokages/blockages In-situ NDT tests like Oxide scale thickness measurement/Boroscope/ hardness etc. at regular intervals 4. HP WELDERS TEST & REJECTION RATE MONITORING In-house testing of HP welders. Monitor HP welder performance through rejection rate. Ensure use of right electrode. Ensure electrodes are baked properly before start of welding

BOILER TUBE FAILURE MANAGEMENT MAINTENACE ASPECTS


5. ADOPTION OF GOOD MAINTENANCE PRACTICES Cleaning of pressure parts by HP Jet Pump & Use of scrapper or wire brush Access Platforms, Safety Appliances etc: Use of quick erect scaffolding for easy access at all places and to carry out extensive erosion survey Tube Cutting using Portable Saw. No gas cutting of tubes. Adequate Protection in case of use of gas for tube cutting. Capping of cut tubes with PVC caps Removal of HAZ by Saw Removal of all Pad Welding & Window Welding Repairs with New Tubes Use of Bend, Shield etc from reputed Vendors. Avoid local/ in situ making Through & Safe Access to all Pressure Part Areas for Inspection & Work Boiler Flushing & Draining and Inspection of Down Comer Headers Cyclic Hydro before Start of Repairs in Old Boilers Keep coil alignment perfect

BOILER TUBE FAILURE MANAGEMENT MAINTENACE ASPECTS


5. ADOPTION OF GOOD MAINTENANCE PRACTICES (Contd.) Use of proper & safe platform at ECO/LTSH area along with coil handling facility Make adequate mechanized arrangement for pent house ash removal if leakage is suspected Tubes/bends to be checked for thru ness before fixing. Header flushing & inspection after completion of OH Avoid stray arcing on tubes. Adjacent tubes are damaged. Care while fin cutting to avoid damage to adjacent tube while cutting Ensure tube/coil alignment during each OH in first and second pass Replace coal nozzles & proper alignment. Repair & proper operation of SADC DMW joint NDT & replacement plans Fin welding by 2.5 mm electrode Avoid fabrication of different types of bends at site

BOILER TUBE FAILURE MANAGEMENT

MAINTENACE ASPECTS
5. ADOPTION OF GOOD MAINTENANCE PRACTICES (Contd) Pressurisation of Re-heater circuit/MS Circuit to check for leakage detection Air testing with Sponge ball for testing of loops/coils Develop experiences based schedule for economizer/ Primary SH etc for coil lifting/inspection/reversal Air testing with Sponge ball for testing of loops/coils Inspection of orifice in FSH area to find the cause of overheating Replacement of spacer tube of platen super heater Replacement of DMW, Clamp, shield in primary SH area Phase wise reversal/replacement of ECO coil with new coils instead of total replacement at one time to achieve low down time Thorough & adequate cleaning of pressure parts to ensure effective heat transfer

BOILER TUBE FAILURE MANAGEMENT

MAINTENACE ASPECTS
5. ADOPTION OF GOOD MAINTENANCE PRACTICES (Contd.) Restore Supports/ clamps which are cut during work Check Looseness of hanger supports & rectify Check for misalignment of the coils. Replace missing/broken connectors. Ensure all coils are aligned Ensure proper fixing of shields and cassette baffles. Replace all improper shield/baffles Use of latest maintenance tools & techniques eg Portable Bevelling Machine, Plasma Arc Cutting Machine, Portable welding Machine, Headers Hand hole plate cutting machine etc Adequate illumination inside boiler. Use of 24 V supplies & pneumatic tools to prevent loss of life due to electrocution. Use safety nets in S-Panel area. Usage of fibre body hand tools Joint inspection along with safety inspector for scaffolding & planks fix up. Load testing of all T&P

BOILER TUBE FAILURE MANAGEMENT

MAINTENACE ASPECTS
6. MISCELLEANOUS AREAS NEED ATTENTION: USE OF PPE & Safety Training to all contract workmen VALVES: All the safety valves are to be serviced and trevi testing done. Actual floating of valves on which maintenance has been carried out should be done. All root valves in the hydraulic test circuit are being serviced and blue matched & witnessed by team of maintenance, operation & quality SOOT BLOWERS: Monitoring of availability of wall blowers & Restoration of LRSB COAL BURNERS: Proper repair hard facing of splitter plates & in side surface/replacement of nozzle etc . Ensure proper alignment of coal/air nozzles.

UNIT OVERHAUL QUALITY ASPECTS

USE OF M-QCP FOR STRUCTURED & PLANNED EROSION SURVEYS


DATA ANALYSIS & TRENDING FOR FUTURE PLANNING & UNIT OVERHAULS

UNIT OVERHAUL QUALITY ASPECTS

USE OF M-QCP FOR STRUCTURED & PLANNED EROSION SURVEYS


DATA ANALYSIS & TRENDING FOR FUTURE PLANNING & UNIT OVERHAULS

UNIT OVERHAUL QUALITY ASPECTS

USE OF M-QCP FOR STRUCTURED & PLANNED EROSION SURVEYS


DATA ANALYSIS & TRENDING FOR FUTURE PLANNING & UNIT OVERHAULS

UNIT OVERHAUL QUALITY ASPECTS

USE OF M-QCP FOR STRUCTURED & PLANNED EROSION SURVEYS


DATA ANALYSIS & TRENDING FOR FUTURE PLANNING & UNIT OVERHAULS

UNIT OVERHAUL QUALITY ASPECTS

USE OF M-QCP FOR STRUCTURED & PLANNED EROSION SURVEYS


DATA ANALYSIS & TRENDING FOR FUTURE PLANNING & UNIT OVERHAULS

UNIT OVERHAUL QUALITY ASPECTS

USE OF M-QCP FOR STRUCTURED & PLANNED EROSION SURVEYS


DATA ANALYSIS & TRENDING FOR FUTURE PLANNING & UNIT OVERHAULS

BOILER TUBE FAILURE MANAGEMENT

MAINTENANCE PREVENTION ASPECTS

PROVIDING WEAR BARS ON S-PANEL


Wear bars on S- panel

cassette baffles protection for economizer bend

ECO COIL PROTECTION SHIELD LOCKING ARRANGEMENT

economizer end erosion use of cassette baffles & refractory for protection

Erosion of SCW bifurcates and its prevention

REVERSAL OF ECONOMIZER COILS

LTSH inlet header- Shielding arrangement on tube surface

use of sacrificing shield

UNIT OVERHAUL MANAGEMENT


Advance Planning: 18 24 month (minimum) Defining Scope Of Work in detail Identification of requirement of resources (Spares, consumables, skill & contracts) Organizing resources in time

Three tier planning system need to be adopted.

STRATEGIC PLANNING & OVERHAUL MANAGEMENT

Life Cycle Plan (LCP) Station Rolling Plan (SRP) Station Location Annual Plan (SLAP)
LIFE CYCLE PLAN (LCP)
Focus on major replacement plan for the entire life cycle of 25-30 years. Covers replacement of the equipment/parts which are likely to fail before or near the life expectancy & have a long lead time.
Examples: super heaters, re-heaters, high pressure valves, safety valves, gear reducers, ash disposal lines, slurry pumps, chemical piping, resins, conveyor belts and drives, coal crushers, turbine rotor blades, turbine bolts, boiler feed pump rotor, H.P. heater coil, H.T. motor, transformer, switch gears, cables, etc.

Replacement plans are conceived on the consideration of Coal quality, Creep life of various components, Equipment duty conditions, Actual Wear rate and Behavioral trend of plant /equipment inspection and RLA reports etc.

LIFE CYCLE PLAN (LCP)


[TYPICAL]

Years 01 02 04 08

Activity Description Statutory Inspection, Coal Burners, APH Seals. Statutory Inspection, Coal Burners, APH Seals. ECO/LTSH bends & tubes, Refractory Statutory Inspection, Coal Burners, APH Seals. ECO/LTSH bends & tubes, Refractory, ESP Electrodes, ID Fan Impellers, Defective Valves Statutory Inspection, Coal Burners, APH Seals. ECO/LTSH bends & tubes, Refractory, ESP Electrodes, ID Fan Impellers, Defective Valves, APH Baskets, PF Bends, ECO/LTSH Coil Reversal, DC Batteries Replacement Statutory Inspection, Coal Burners, APH Seals. ECO/LTSH bends & tubes, Refractory, ESP Electrodes, ID Fan Impellers, Defective Valves, APH Baskets, PF Bends, ECO/LTSH Coil, DC Batteries HP/IP Turbine Casing Studs, HP/IP CV/GV Bolts, Turbine Bearings, Turbine Inter stage seals, Electrical Cables, Control Cables Statutory Inspection, Coal Burners, APH Seals. ECO/LTSH bends & tubes, Refractory, ESP Electrodes, ID Fan Impellers, Defective Valves, APH Baskets, PF Bends, ECO/LTSH Coil, DC Batteries HP/IP Turbine Blades, Diaphragm, Casing Studs, HP/IP CV/GV Bolts, Turbine Bearings, Turbine Inter stage seals, Electrical Cables, Control Cables, Heaters/Condensers/ Heat Exchangers tubes/tube nest etc.

16

25

STATION ROLLING PLAN (SRP)


Station rolling plans are drawn on six year spread so that capacity outage is optimized to match the regional grid demand.
The first two-three years should be planned and presented in detail. The subsequent three years shall be indicative. These plans are updated every year in a rolling manner

Rolling Plan of a Thermal Station (Typical)


Stn/Unit Cap Last O/H Done XXX Unit-1 500 HPT IPT LPT Gen Blr 500 HPT IPT LPT Gen Blr 1000 27-Nov-03 23-Oct-01 23-Oct-01 27-Nov-03 27-Nov-03 1-Oct-97 9-Oct-02 9-Oct-02 9-Oct-02 29-Sep-03 From To Duration O/H Type 12-Aug-05 29-Aug-05 18d Boiler 12-Aug-06 12-Aug-07 29-Aug-06 11-Sep-07 18d 30d Boiler Blr+IP+LP 12-Aug-08 29-Aug-08 18d Boiler 12-Aug-09 6-Sep-09 30d B+HP FY 2005-06 FY 2006-07 FY 2007-08 FY 2008-09 FY 2009-10

Unit-2

From To Duration O/H Type P/M (%)

12-Sep-05 29-Sep-05 18d Boiler 4.93

12-Sep-06 29-Sep-06 18d Boiler 4.93

12-Sep-07 1-Sep-08 29-Sep-07 30-Sep-08 18d 30d Boiler Blr+IP+LP 6.57 6.55

12-Sep-09 29-Sep-09 18d Boiler 6.57

Total

STATION LOCATION ANNUAL PLAN (SLAP)


It provides an accurate assessment of generation & unit outage plans for the year. OBJECTIVE: is to identify all the constraints to achieve the generation level and organize resources for effective operation and maintenance. It requires technical assessment of the units capability and plan unit overhauls.
It also identifies interface with OEM, manufacturing facilities and skill requirements

STATION LOCATION ANNUAL PLAN (TYPICAL)


Statn Unit Inst. Cap. MW

2006-2007 June July Aug Sept Oct Nov Jan Feb

xxx

1 2 3 4 5 6

00 00 00 00 00 00
1/6 to 30/7 10/9 to 30/10

1 to 20/11 1 to 20/2

UNIT ANNUAL OVERHAULS PLANNING PROCESS


The cost of unit overhauls in terms of generation loss are very high Adequate work and resource planning for unit overhauls in an integrated manner is essential to avoid last minute shock and surprises as also to have reliable performance of the unit after overhauls.
THE DECLARATION OF UNIT OVERHAULS SUBSEQUENT TO ANY FORCED OUTAGE HAS TO BE AVOIDED BECAUSE OF ITS UNDESIRABLE AFFECTS ON RESOURCE AVAILABILITY AND UNPREPARED EXECUTION.
ONLY OUTAGES BUDGET UNDER STATION LOCATION ANNUAL PLANS SHALL BE TERMED AS PLANNED OUTAGE. ALL OTHER OUTAGES SHALL BE TERMED AS FORCED OUTAGE

OBJECTIVES OF UNIT OVERHAUL PLANNING QUALITY FOR RELIABILITY (O2O MAINTENANCE) OPTIMIZE TIME SCHEDULE & COST

Overhaul planning process is initiated with Engineering Declaration 18-24 months in advance. The planning process of any unit outage has essentially three stages: X Pre Shut down Planning activities X Shut down activities X Post shut down activities

PLANNING PROCESS FOR UNIT OVERHAUL


Pre shut Down Planning (24 M) Monitoring Sheets (12 M) Job List (24M) Bill of Material Skill & Manpower Indent & Procurement (18 -24 M)

Skill Resource Analysis (18 M) PERT Net work (12-18 M)

Tender & Contracts (12 M) Resource Mobilization (1 M)

Maintenance QCP (12 M)

Isolation Plans (6 M) Recommissioning Check sheets (12 M)

Pre Outage Survey (15-30 D)

Quality Checks UNIT OFF LOAD

Re commissioning checks Post OH Review UNIT ON BAR

Overhaul Execution

OUTAGE COMPLETION REPORT (1 M)

Overhaul Monitoring

ENGINEERING DECLARATION
Engineering Declaration of the unit includes brief review of the past performance of the unit, define objectives of the proposed overhaul and the quantified projections of the return in terms of gain in reliability and efficiency.
The first Engineering Declaration is issued 18-24 months ahead of units planed overhaul. Periodic review of outage preparedness facilitates revisions of the plan if any.

OVERHAUL MANAGEMENT ORGANISATION (OUTAGE COMMITTEE)


This committee will be responsible to conduct the overhaul of all the units of a station during a particular financial year as planned and shall ensure that all the jobs are carried out as per laid down specifications and quality plans. The committee may change for next financial year according to availability of personnel and workload of the station.
The various members of the outage team shall be as follows: a. Outage manger d. Executive: BMD g. Executive: C&I j. Executive: MMS b. Executive: Long Term Planning e. Executive: TMD h. Executive: Electrical k. Executive: Operations Efficiency c. Executive: Contracts f. Executive: BoP i. Executive: Operations l. Executive: Materials

Members from Finance, HR etc are drawn as deemed necessary.

OUTAGE COMMITTEE FUNCTIONS


(a) To assess skill availability and the technical capability of the contractors. (b) To coordinate amongst different working departments and contractors. (c) To Check and ensure that the job execution is as per technical specification and work quality is being complied as per Maintenance Quality Checks & Protocol (M-QCP) Sheets. (d) To ensure observance of safety rules as per laid down principles of the company. (e) To monitor work progress to ensure timely work completion, reduce down time and cost. (f) To ensure optimum utilization of resources. (g) To coordinate for an effective work control. (h) To facilitate de-bottle necks in planning and take appropriate measures for improvements and effective planning.

OUTAGE PREPAREDNESS INDEX (OPI) OUTAGE COMPLETION REPORT (OCR)


OUTAGE PREPAREDNESS INDEX (OPI) : is devised to be a tool to measure the Degree Of Preparedness to execute the planned outage. OPI provides a quantified measure of the Degree of Preparedness for planned outage of a given unit overhaul. OPI monitoring shall begin 18 -24 months in advance of the proposed planned date of Unit overhaul. OVERHAUL COMPLETION REPORT (OCR) : Each completion report should bear a unique number for identification. The cross reference of the completion report should be entered in the equipment history. Each section shall contain detail of work undertaken, surprises observed, new methods & fixtures used, quality checks & protocol sheets and shall contain following sections
SECTION-1: EXECUTIVE SUMMARY SECTION-2: BOILER & AUXILIARIES SECTION-3: TURBINE & AUXILIARIES SECTION-4: GENERATOR & AUXILIARIES SECTION-5: ELECTRICAL EQUIPMENTS SECTION-6: CONTROL & INSTRUMENTATION SECTION-7: OFFSITES AND MISCELLANEOUS SECTION-8: RE- COMMISSIONING & EFFICIENCY EVALUATION WITH COST BENEFIT ANALYSIS SECTION-9: MANPOWER & BUDGETS SECTION-10: CONCLUSIONS AND RECOMMENDATIONS

Need of Professionalism in maintenance


X NEED BASED MAINTENANCE & QUALITY APPROACH:
It is essential that maintenance needs are condition based, even in boiler also. All maintenance activities must have a requisite maintenance quality checks & protocols (M-QCP) - by maintenance.

X OPPORTUNITY MAINTENANCE TO AVOID SUDDEN SHOCKS:


Ever preparedness & Judicious decisions to carry out opportunity based maintenance to avoid partial loading & to address pending defects & pre-scheduling of PM etc. should be governed by economic considerations.

X KNOWLEDGE BASED MAINTENANCE:


The basic beliefs about age of the plant asset and its impact on failure As things got older, they were more likely to fail have also begun to change. The concept of `infant mortality & bathtub" curve has come in for a change. Today it is understood that need based quality maintenance with technological improvements can contain the failures. It involves a diagnostic process with of analytical approach. MAINTENANCE PRACTICES & METHODS NEED A CONTINUOUS REVIEW & UPDATE.

BOILER TUBE FAILURE MANAGEMENT

DESIGN ASPECTS
1. Reduced flue gas velocity
Erosion=(Velocity)2.6, Preferred Velocity=10m/sec

2. Smooth change in flue gas velocity


Reduced flue gas velocity in second pass reduces fire side heat transfer coefficient and hence the requirement of heat transfer area increases. It also increase the fouling tendency on horizontally placed tubes in the second pass thus reducing the heat transfer further. Therefore flue gas velocity need to be carefully optimized. Change in flue gas velocity or direction may affect the erosion rate in new areas

3. Reduced SH/RH spray:


High spray also causes thermal shocks to headers, stubs & tubes.

4. Reduced operating limits of tube metal temperatures 5. Use of suitable material to avoid dissimilar metal welds (DMW) joints
Use of inconel as filler material for root weld reduces failure frequency of austenitic/ ferritic joint , SA 213 T91 avoids use of DMW but making a T91 joint is complex.

THANK YOU

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