Rankine Cycle
Supercritical Rankine
Cycle
3740 C;
225
Kg/cm2
Enhanced steam
parameters require
superior materials
Requirements of
materials for hightemperature application
4.
Requirements of materials
for high-temperature
application (contd.)
Comparison of allowable
stresses between conventional
and advanced materials
Supercritical Boiler
Item
Section
Material Specification
(ASME)
Water Wall
Tubing
SA213-T22
SA335 - P12
SA335 - P91
SA213-T12
Superheater
Tubing
SA213-T23
SA213-T91
SUPER 304H
SA106-C
SA335 - P12
SA335 - P91
SA210Gr.C
Reheater
SA213-T12
Tubing
SA213-T23
SA213-T91
SUPER 304H
SA106-C
Tubing
SA210-C
Economiser
Seperator Storage Tank
SA302-C
Various damage
mechanisms in supercritical
boilers
Short term damage
mechanisms:
Operational effects on
supercritical boiler
components
Manifestation
Mechanical
Material loss
Wall thinning
Weld defect
Crack
Swelling
Slagging, fouling
Loss of material strength
Manifestation
(contd.)
Metallurgical
Creep life
Structural integrity
Steam Starvation
Sudden Rupture
Various damage
mechanisms and suitable
NDE
methods
Damage Mechanism
NDE Methods for detection
Erosion
Fibroscopy
Welding defects
Creep
Swelling
What is Creep?
-The time dependent,
thermally assisted
deformation of components
under load (stress) is known
as creep.
Structural
Classificati
on
Expended
life
fraction
None
0.12
Isolated
cavities
0.46
Oriented
cavities
Macro cracks
Immediate repair
1.00
In-situ metallography
Major Findings
Bulging
Damaged microstructure
Fatigue
Start-ups, load
changes
CRACK
PROPAGATION
Initial
Crack length
Assessed by a suitable NDE
technique (e.g. Ultrasonic)
Critical
Crack length
Assessed based on the
prevailing stress field and
geometry of the job.
Crack propagation
Paris Law:da/dN = c kn
material
c , n =
PCS
Scan Motion
Positional Encoding
Tx
Rx
Diffracted
Signals
Lateral Wave
Backwall Reflection
RF Waveform
Tx Signal
Amplitude
Quantisation
WT
Phase Reversal
Time of Flight
Weld Length
t LW
t BW
t1
t2
S2 T 2
S x 2aZ
C
T H 2 x 2 a B 2
C
S2 d2
S 2 d h 2
d H 2 x 2 a B2
C
d h H 2 x 2 a B 2
C
Indian Boiler
Regulation (IBR)
Statutory Perspective
Objectives:
1. Safe Operation
2. Update Boiler memo
TABLE -1
Component
Visual
Ultrasonic
testing
Magnetic
Particle
Inspection
Liquid/
Dye
Penetrant
Inspection
Replication
Sampling
Deposit
Analysis
Outside
Diameter
And
Thickness
Fibroscopic
Inspection
Hardness
Other
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Drum(Steam)
Yes
Yes
No
Yes
Yes
No
Yes
Yes
No
Yes
Water Drum
Yes
Yes
No
Yes
Yes
No
Yes
Yes
No
Yes
Low Temp.
Headers
Yes
No
No
Yes
No
No
No
Yes
Yes
Yes
Attemperator
Header
Yes
Yes
No
Yes
Yes
No
No
Yes
Yes
Yes
High Temp.
Economiser
tubes
Yes
No
No
No
No
Yes
No
Yes
No
No
Low Temp.
Economiser
tubes
Yes
No
No
No
No
Yes
No
Yes
No
No
Convection
Superheater
coils
Yes
No
No
No
No
Yes
Yes
Yes
No
Yes
Primary
Super heater
coils
Yes
No
No
No
No
Yes
No
Yes
No
Yes
Pre final
Super heater
coils
Yes
No
No
No
No
Yes
No
Yes
No
Yes
Swell
measur
ement
TABLE -1 (Contd.)
Component
Visual
Ultrasonic
testing
Magnetic
Particle
Inspection
Liquid/
Dye
Penetrant
Inspection
Replication
Samplin
g
Deposit
Analysis
Outside
Diameter
And
Thickness
Fibroscopic
Inspection
Hardness
Others
Final
Super heater
coils
Yes
No
No
No
No
Yes
No
Yes
No
Yes
Reheater coils
Yes
No
No
No
No
Yes
No
Yes
No
Yes
High Temp.
headers
Yes
Yes
No
Yes
Yes
No
No
Yes
Yes
Yes
Final
Super heater
header
Yes
Yes
No
Yes
Yes
No
No
Yes
Yes
Yes
Swell
measur
ement
Reheater
header
Yes
Yes
No
Yes
Yes
No
No
Yes
Yes
Yes
Swell
measur
ement
Main steam
Piping
Yes
No
No
No
Yes
No
No
Yes
No
Yes
Platen super
Heater header
Yes
Yes
No
Yes
Yes
No
No
Yes
Yes
Yes
Primary super
heater header
Yes
Yes
No
Yes
Yes
No
No
Yes
Yes
Yes
TABLE -1 (Contd.)
Component
Visual
Ultrasonic
testing
Magnetic
Particle
Inspection
Liquid/
Dye
Penetrant
Inspection
Replication
Sampl
ing
Depo
sit
Anal
ysis
Outside
Diamet
er
And
Thickn
ess
Fibrosc
opic
Inspecti
on
Hardness
Economiser
Header
Yes
No
No
Yes
No
No
No
Yes
No
No
Auxiliaries
Yes
No
No
No
No
No
No
Yes
No
No
Boiler Bank
Tube
Yes
No
No
No
No
No
No
Yes
No
No
Water Wall
Yes
No
No
No
No
Yes
No
Yes
No
No
Furnace Water
Wall
Yes
No
No
No
No
Yes
No
Yes
No
No
others
Table 2.
Component
Visual
Ultrasonic
testing
Magnetic
Particle
Inspection
Liquid/
Dye
Penetrant
Inspection
Replicatio
n
Samplin
g
Deposit
Analysis
Outside
Diameter
And
Thickness
Fibroscopic
Inspection
Hardness
Drum(Steam)
Yes
No
No
Yes
No
No
No
Yes
No
No
Water Drum
Yes
No
No
Yes
No
No
No
Yes
No
No
Economiser
Tubes
Yes
No
No
No
No
Yes
No
Yes
No
No
Convection
Super Heater
coils
Yes
No
No
No
No
Yes
No
Yes
No
No
Primary Super
Heater coils
Yes
No
No
No
No
Yes
No
Yes
No
No
Final Super
Heater coils
Yes
No
No
No
No
Yes
No
Yes
No
No
High Temp.
Headers
Yes
No
No
Yes
Yes
No
No
Yes
Yes
No
Other
Non
destru
ctive
oxide
thickn
ess
inspec
tion
TABLE -2 ( Contd.)
Final Super
Heater Header
Yes
No
No
Yes
Yes
No
No
Yes
Yes
No
Economiser
Header
Yes
No
No
No
No
No
No
Yes
No
No
Auxiliaries
Yes
No
No
No
No
No
No
No
Yes
No
Boiler Bank
Tube
Yes
No
No
No
No
No
No
Yes
No
No
Water Wall
Yes
No
No
No
No
Yes
No
Yes
No
No
Main steam
Piping
Yes
No
No
No
No
Yes
No
Yes
No
No
Swell
measu
remen
t
OUTCOME
Issues of Supercritical
Technology in India
Issues of Supercritical
Technology in India
(contd.)