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ECONOMISER TUBE LEAK IN BOILER # 6

DATE - 26.09.05

10/30/06

E:/wkg_fdr/ppt/slide_prsnt1.ppt

Incident Detail

Sl. No.

Section

Date and Time Date and time Shift of Incident of normalise

Shift Incharge

Operator Incharge

Equipment Description

Subequipment detail

Brief Incident Description

PH3

26.09.05, 12:35 Hrs

29.09.05 05:20 Hrs

A. Seal

Jitu Ram

Boiler#6

Economiser

Boiler 6 Economiser tube leakage

Failure Location Detail

1st coil of middle bank (ESP side), 15th row from top had developed a 1.5 mm dia. pin hole.

This was between 2nd and 3rd column (from Boiler-5 Economiser , behind a cross beam.

side) of

TUBE LEAKAGE AREA

Economiser of Boiler #6

Leakage area

ESP

Back

Economisers Middle Bank Tubes

Pin Hole

Back

Function of Economiser

To preheat the feed water of Boiler. Water is supplied at the inlet manifold of Economiser, which after passing through the tubes, goes into the Economiser outlet manifold.In the process water picks up heat from the flue gas.Hot water then goes into the steam drum.

Line Diagram
Spray water Sup. Steam to TG Attemperator

Flue Gas

UPPER DRUM

Sec. Sup. Pry. Sup.

B. B. TUBES

Economiser

Boiler

Gen. Tube

LOWE R DRUM DOWN COMER

Feed Water
CHECK VALVE

I.D.Fan

Stack

STOKER FRONT SHAFT REAR SHAFT

FEED WATER CONTROL STATION

OBSERVATIONS
Probable Causes Normal Condition Inlet water temp. 1150C Outlet water temp. 2540C Inlet feed water press. <81 Kg/Cm2 Inlet feed water flow 68 Tons/hr. Inlet flue gas temp. 4250C Outlet flue gas temp. 1770C Observation Inlet water temp. 1130C Outlet water temp. 2100C Inlet feed water press. 68 Kg/Cm2 Inlet feed water flow 69 Tons/hr. Inlet flue gas temp. 4060C Outlet flue gas temp. 1780C Remarks / Action Taken

Deviation from operating parameter

No abnormal deviation found

Tubes thinning

No thinning on straight portion of Tube thickness measured & the tube. found o.k (original thickness 3.66 Thinning <1 mm for bend portion. mm) near the failed tube area.

Thickness gauging was also carried out at bottom, top and middle levels of economiser tubes during RLA study by M/S TBW. There was no abnormal thinning.

OBSERVATIONS
Probable Causes Normal Condition Observation Remarks / Action Taken - No corrosion / pitting was observed when tested during RLA study (03/09/05 to 08/09/05) done by M/S TBW, Pune. Since then there is no change in water quality. Corrosion inside is ruled out. - No action - No corrosion / pitting was also observed when tested during RLA study (03/09/05 to 08/09/05) done by M/S TBW, Pune. - No action

Corrosion internal

No corrosion on surface.

Could not be seen inside.

Corrosion external

No corrosion on surface

- No corrosion

OBSERVATIONS
Probable Causes Tubes poor Metallurgical state Normal Condition Observation Remarks / Action Taken

- Not checked. Tubes grade BS3059 1978 PT- During RLA study it was found 2 S2 440 Cat.-2 that tubes are of specified grade Micro structure Normal and of normal micro structure External flue gas erosion marks were present on the leaking tube and four other tubes nearby.

No action

Tubes erosion

No erosion on surface

Check for localised high flue gas velocity. (considering there is no change in fuel quality) Less spacing between skin plate and the tube caused localised high flue gas velocity lead to corrosion. Baffle to be provided

Tube pitch 75 mm Spacing between skin plate and Localised high tube 60 mm flue gas velocity (Considering no change in boiler parameter)

Tube pitch found ok. Spacing between skin plate and tube approx 40 mm

Thickness Measurement

Pin Hole

Back

Errosion Marks on tube


Severe Erosion marks

Pin Hole

Back

Root Cause

Erosion of tubes by localised high flue gas velocity. The gap between Economisers skin plate and the failed tube area was relatively less causing relatively high flue gas velocity in that zone.

Corrective Action

The pin hole was rectified by metal buildup by high welder.

pressure

The other eroded portion of the tubes (4 nos.) were also rectified by metal buildup by high pressure welder. Hydraulic test was done and found no leakage from the Economiser tubes.

Corrective Action

Rectified area
Back

Preventive Action

To prevent high speed flue gas to escape in between the skin plate and

outer most tube surface, baffle plates were provided on the top of each bank so that chances of erosion in the outer most tube will get reduce. Similar baffle plates will be provided in other Economiser during its Mapping is done for all the failed Economiser tubes. All the failed tubes and the tube portions which having less thickness than the desired, will be rectified during Boiler Gas Conversion. Monitor thickness of bend and straight portion of the tube annually. * In these case too, the fact remains that many areas of Economiser coils are not approachable for testing as well as these area are prone to errosion. shutdown.

Preventive Action

Skin plate High velocity area

Baffle plate

Back

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