1. Condition Assessment (CA) & Residual Life Assessment (RLA) Studies 2. Thermal Performance Test (TPT), If Necessary
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Intent of RLA
Restoration / up-rating of Generation capacity on a continuous, safe and reliable basis. To increase unit availability and reliability on Sustainable basis to meet the current requirements like ABT. Achieving rated or better efficiency of the unit so that the COG remains competitive. Achieving an extended competitive plant-life of another 15 years at least. To improve safety of plant and personnel. To meet current statutory and environmental norms.
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CA & RLA
REVIEW OF OPERATIONAL HISTORY OF EQUIPMENTS:
Details of start up and Shut down Operational Regime Maintained Duration and extent of parameter escalation Steam temperature and water Chemistry Observation During Planned Shut downs Replacements during routine maintenance and forced outages Detailed Metallurgical Analysis Analysis/Reports on premature failures
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CA & RLA
Pre Outage Planning and Survey:
Record nameplate details & general description of all equipments Compilation of design details Review of these compiled data and assess the present condition of equipment /system
CA & RLA
Visual Examination:
To detect signs of overheating of tubes, for swelling, blistering and warping To identify signs of corrosion or erosion To examine convection pass tube banks for detection of misalignment of tubes To assess condition of all headers for ligament cracks etc. To determine the condition of components in the penthouse including header supports and structural members To determine boiler setting integrity Examination of drum internals
Dimensional Measurement:
The components liable for deformation or distortion due to wear / creep namely, headers, pipes, hangers, support structures etc. are to be thoroughly cleaned and dimensions to be measured to compare with original / previous record.
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CA & RLA
Videoscopic Inspection :
Videoscopic examination of all header internals. Digital photographs are taken of each header internal surface and each header / stub connection. Videoscopic examination determines the following: a) Internal cracks on headers/nipples/stubs/ ligaments b) Condition of internal cleanliness c) Oxide scale
Non-Destructive Tests :
Dye- penetrant Examination (DPT) Dye-penetrant examination using fluorescent dye are used for detection of surface crack / porosity / discontinuity of header ligament joints, pipe weld joints, attachment weld joints, valve body / spindle / seal etc.
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CA & RLA
Non-Destructive Tests (Contd.):
Magnetic Particle Inspection (MPI) Magnetic particle inspection using wet fluorescent method shall be employed for detection of surface and sub-surface crack / discontinuity of header ligament joints, pipe weld joints, attachment weld joints, valve body / spindle / seal etc. In case of detection of any crack, the depth shall be measured with the help of crack depth meter based on electrical potential drop principle or ultrasonic principle
Ultrasonic Examination (UT) Ultrasonic Examination method shall be employed for detection of sub-surface crack, loose bonding, stress cracking or any kind of discontinuity mainly in the longitudinal and circumferential seams of the boiler drum, girdling loops of all high temperature tube panels, butt weld joints, attachment welds and stub joints of the steam & water headers & pipes etc.
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CA & RLA
Non-Destructive Tests (Contd.):
In situ oxide scale measurement It is a high frequency ultrasonic method which is to be carried out at various locations, especially in the tubes where the metal temperatures are maximum, in the platen & final superheater and reheater assemblies. Furnace Corrosion & Thickness Mapping Continuous tube OD scanning method based on low frequency electro-magnetic principle to carry out the detail thickness and corrosion mapping of all the accessible tubes in the furnace zone Metallographic Replication (RPL) Metallographic examination by portable optical microscope and surface replication technique are carried out to assess the present microstructure condition of the components subjected to damage due to creep, temper embrittlement, stress corrosion cracking and thermal fatigue (low cycle fatigue).
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CA & RLA
Non-Destructive Tests (Contd.):
Hardness Testing Hardness testing of tubes, weld joints, headers, pipes etc. are carried out, wherever required, to ascertain any change in metallography and to find out residual stresses. Hardness measurement are to be compulsorily taken at the spots where replica has been taken In-Situ Chemical Analysis (CA) In-situ chemical analysis is to be employed for determining and categorizing the steel grade of various superheater and reheater coils with the help of instruments based on either Optical Emission Spectroscopy (OES) principle or radioisotope excited x-ray fluorescence analyzer.
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CA & RLA
Destructive Tests:
Tube samples and tube deposits from various boiler locations along with boiler drum deposit are collected for destructive tests. These are analyzed at reputed laboratories for: Stress rupture test for mechanical properties Microstructure evaluation to find out metallurgical degradation Chemical analysis of deposits
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Recommendations
After collection of the various data as discussed and analysis thereof remaining life of the boiler is calculated & recommendations are given accordingly.
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To analyze the data collected and compare with predicted performance data
To identify shortfalls in performance and causes for the same.
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R&M of Boiler
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Pri S/H 7%
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Interactive Issues
Reheater Temp. C ontrol Dampers Air Ingress C oal Q uality Deterioratio G as Temp. High G as Q uantity High M ill C apacity
PA Fan C apacity
Economizer erosion
S - PA Air A M ismatch
S econdary C ombustion
Boiler Efficiency
Tube Failures
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Areas
* ESP
* Spares Inventory
* Burners
Reasons
* Higher unburnt
* Coal Quality
* Unavailability of genuine spares / OEM spares * Quality of spurious spares * Design deficiency in Turbine
* Air Ingress
Remedies
* Replacement of furnace with membrane panels * Pent house sealing with improved design
* Increasing the height of fields / adding parallel stream * Installtions of improved burners / Low Nox burners
* Improved Efficiency
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* Life extension
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HeadersCreep , Superheater & Thermal Reheater fatigue Pipes MS & RH Tubes-Furnace wall, Superheater & Reheater
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2 3 years 13 weeks (large headers),6-9 weeks (small headers) 10-12 weeks (for complete superheater or Reheater units)
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18 months
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continue
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U#1 & 2 mills replaced with mills & PA fans of units # 3&4 3 nos. New mills provided for U # 3 & 4 (One old mill retained)along with hot PA fans Reconditioning of suction mill of U#5 Mill loading reduced to 80% at Max. load to take care of burner heat input New Civil foundation and PF pipes for all units Wind Box New Wind Box of improved design provided for all units.
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Boiler # 1 Boiler # 3 Boiler # 5 Sl. Description Unit Guarante Achiev Guarante Achiev Guarante Achiev No. ed ed ed ed ed ed 1 Thermal Efficiency % 86.11 89.91 86.7 88.62 84.95 88.34 (Corrected) 2 Steam Generation TPH 124.9 137.06 253 270.34 258 259.46
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THANK YOU
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Summary Table
Out Liquid Mag side Dye Depo Fibre Ultra netic DiaVis Pene Repli Samp sit Optic Component sonic particle metre ual trant cation ling Anal inspec testing inspec and inspe ysis tion tion. thick ction ness 1 2 3 4 5 6 7 8 9 10 Drum (Steam) Yes Yes No Yes Yes No Yes Yes No Water drum Yes Yes No Yes Yes No Yes Yes No Low tempeYes No No Yes No No No Yes Yes rature header Attempertion header High temperature economiser tubes Low temperature economiser tubes Convection superheater coils Primary superheater coils Yes Yes No Yes Yes No No Yes Yes
Hard ness
Others
12
Yes
No
No
No
No
Yes
No
Yes
No
No
Yes
No
No
No
No
Yes
No
Yes
No
No
Yes
No
No
No
No
Yes
Yes
Yes
No
Yes
No
No
No
No
Yes
No
Yes
No
Yes
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Prefinal superheater coils Final superheater coils Reheater coils High temperature headers Final superheater header Reheater headers Main steam piping Platen superheater header Primary superheater headers Economiser header Auxilliaries Boiler bank tubes Waterwall Furnace waterwalls
Yes
No
No
No
No
Yes
No
Yes
No
Yes
No No Yes
No No No
No No Yes
No No Yes
Yes Yes No
No No No
No No Yes
Yes
Yes
No
Yes
Yes
No
No
Yes
Yes
Yes
Yes No Yes
No No No
Yes No Yes
No No No
No No No
Yes No No
Yes No No No No No
No No No No No No
Yes Yes No No No No
Yes No No No No No
No No No No Yes Yes
No No No No No No
Yes No No No No No
Yes Yes No No No No
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500 MW BOILER - RESIDUAL LIFE ASSESSMENT - EXTENT & QUANTUM OF TESTS Sl. No. Component VE DC ME & H TM DPT MPI FMPI on two longitudinal and four circumferencial welds. MPI at (sat.steamraiser tube dia 127 mm stubs : 89nos.,safety valve -6, Down comer-6, Feed nozzle-3 & other tap off34) 144 welds UT / IOT On two longitudinal and four circumferencial welds, at all tap off stub joints/ Butt joints (sat.steam-raiser tube dia 127 mm stubs : 89nos.,safety valve -6, Down comer-6, Feed nozzle-3 & other tap off-34) 144 welds
Steam Drum
Visual Examinatio n
On two longitudinal and four circumferencial welds, at all 4 spots of tap off stub longitudinal seam joints weld & 4 spots of 6 locations (sat.steamcircumferencial along the length raiser tube dia seam welds - 8 127 mm stubs No. : 89nos.,safety valve -6, Down comer-6, Feed nozzle-3 & other tap off34) 8 locations 6 spots 144 welds At twenty locations attachment welds at burners, wind box, wall blowers at accessible locations
6 locations
Water wall
At burners, soot blowers, Visual bottom ash Examinatio hopper, Z panel n and goose neck area
at burners, soot blowers, bottom ash hopper, Z panel and goose neck area on 10 tube samples
at burners, soot blowers, bottom ash hopper, Z panel and goose neck area
10 Samples
1000 spots
At 20 locations
Visual On all water One sample each on attachment At six locations Examinatio wall hanger and from hanger tube welds at along the length n screen tubes & screen tube random
236 tubes
2 samples
1416
spots
10 locations
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Visual Examinatio n
Total -4 Nos
on 8 circumferencial welds
12 locations
4 locations
10 locations
8 welds
8 welds
8 welds
Water wall outlet headers, steam cooled wall headers and riser tubes
On On circumferencial On circumferencial welds at WW circumferencial W.W outlet welds at WW Visual Hardsness on outlet -12, welds at WW 8, SCW outlet10 locations outlet -12, Examinatio 46spots,Replicas SCW outlet-9, outlet -12, SCW 6, Raiser tubesalong the length SCW outlet-9, n SCW -4, WW- 2. Raiser tube outlet-9, Raiser 20 Raiser tube 20, & Stubs & tube -20, Total 41 20, Total 41 lugs: 150 Total Nos. Nos. 191 Nos. Replica-6 spots Hardness-46 spots on two tube samples 2 Samples
10
41 welds
41 welds
Economiser assemblies
Visual Examinatio n
On On circumferencial circumferencial welds at Eco On welds at Eco inlet - 4, Eco circumferencial inlet - 4, Eco outlet -6, Eco welds at Eco outlet -6, Eco Header stubs inlet - 4, Eco Header stubs & gamma outlet -6, 100 Nos at plugs-100 Nos Random at Random 110 welds 110 welds 10 welds
6 locations
4 welds (min)
10 locations(min)
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Visual Examinatio n
on all on all coils attachment along the length welds near roof at six locations and crown 1416 Nos plate welds at Random 20% 25 crown plates of 6 tubes each On circumferencial welds at LTSH Circumferencia inlet -2, LTSH l welds at outlet -4 and LTSH inlet -2, gamma plugs. LTSH outlet-4 Stubs : 200nos. 206 welds 6 welds
Internal oxide scale measurement covering all coils and terminal tubes (Top & Bottom elevations) - 708 spots 708 spots
2 samples
Visual Examinatio n
6 locations
4 locations
6 locations
6 welds
10
Visual Examinatio n
Replica-2Nos
Circ.weld:Desu Desuperheaterperheater8,spray tube - Circ.weld:Desupe 8,spray tube 6 locations 2, thermowells rheater-8,spray 2, thermowells along the length -6,100% on all tube -2, 6,100% on all liner bolt welds thermowells -6 liner bolt welds & gamma plug & gamma plug
6 locations
2 locations
6 locations
30 welds
30 welds
16 welds
11
Radiant roof header-7,LTSH Radiant roof Radiant roof support headerRadiant roof Radiant roof 7,LTSH headers -2, 4,ECO support Radiant roof Visual headers -2, LTSH 4,LTSH support support LTSH support header-8, 7,LTSH support Examinatio support header header 4, Eco header/ Eco header -4, Eco Flourscent header 4, Eco n 2, Eco support support header - support header support header MPI on Eco support header -8 header - 2 8 -8 & Stubs : 8 support header 200nos. stub-1096 stub joints 14 locations 6 locations 16 lcoations 215 welds 1120 welds (min) 19 welds
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Visual Examinatio n
by sampling -
on all the six panels- 888 Nos including bends at pent house
on DMW joints, roof seal band weld and crown plate welds at roof at Random 20%.
1.Institu oxide scale measurements covering all panels 400 spots in penthouse& in furnace. 2. UT of girdling loops 12 No. for checking stress cracking 400 spots & UT of 12 girdling loop
444 tubes
2 samples
888 spots
444 bends
13
by sampling-2 Nos
432 tubes
2 samples
on DMW welds, roof seal band on all tubes and welds, crown covering all plate welds at coils-864 Nos roof and attachment welds Random 20% 30 butt welds, 864 spots crown plates of 6 panels
Insitu oxides scale - 200 Nos, on 24 girdling loops for stress cracking and 6 binding loops
230 locations
14
A)On 200 stub A)On 200 stub jointsB)Circum jointsB)Circumf ferential weld A)Circumferential erential weld at 6 locations at Inlet header weld at Inlet Inlet header -6, along the 6, outlet header -6, outlet outlet headerPlaten length, header-10, header-10, SHDP Visual SH InletHeader - SH InletHeader - 10, SHDP to superheater including swell SHDP to to platen Examinatio 2,SH outlet 2,SH outlet platen inlet and measurements platen connection-5, n Header -4 Header -4 connection-5, outlet headers outlet header connection-5, Drains and vents Drains and 4, inlet header Drains and stub-4 and vents stub-4 2 vents stub-4 gamma plugs and gamma and gamma plugs plugs
6 spots
6 spots
6 spots
225 welds
225 welds
25 welds
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15
Visual Examinatio n
On 50 DMW joints, Final RH-1472, attachment Half RH- 1472 welds and covering all crown plate panels welding 20% at random 50 butt welds,crown plates of 10 panels of full & half RH
on girdling loops for stress cracking at random , Insitu oxide scale analysis 1400 points
920 tubes
2944 spots
1400 locations
16
Divisional superheater headers and reheater headers ( inlet, intermediate and outlet headers)
Visual Examinatio n
Division Panel Division Panel inlet-12, DP inlet-12, DP Div.SH Inlet : 2 & outlet-12,Wall outlet-12,Wall Outlet : 2 RH inlet-2,RH RH inlet-2,RH RHInlet header-4 , Platen inletPlaten inletoutlet -4 14,RH outlet-4, 14,RH outlet-4, RH links-4 RH links-4
On circ. weld On circ. weld joints at SHDP joints at SHDP On circ. weld inlet -6, SHDP inlet -6, SHDP joints at SHDP outlet-8,Wall outlet-8,Wall inlet -6, SHDP RH inlet-4,RH RH inlet-4,RH outlet-8,Wall RH Platen inletPlaten inletinlet-4,RH Platen 12,RH outlet12,RH outletinlet-14,RH outlet10 and 400 10 and 400 12 nipple welds & nipple welds & gamma plugs gamma plugs
36 spots
12 spots
36 spots
40 butt welds 40 butt welds and 400 nipple and 400 nipple welds welds
44 butt welds
17
Visual Boiler integral Examinatio piping (carbon n steel) and down comer
Replica-2 Nos
Minimum one At At At circumferential on each integral circumferential circumferential welds piping welds welds
12 locations
2 spots At SH connecting link-2 Nos, MS piping from boiler to stop valve4Nos 6 spots
12 spots
12 welds MS-4, Thermowell stub-4, safety valve / ERV stub -14 22 welds
12 welds MS-4, Thermowell stub-4, safety valve / ERV stub -14 22 welds
12 welds MS-4, Thermowell stub4, safety valve / ERV stub -14 22 welds
18
Visual Boiler integral Examinatio piping(alloy n steel including MS upto stop valve)
MS -4 Nos
MS -4Nos
4 locations
4 spots
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Main Steam, Hot reheat MS-6,HRHand cold 14,CRH-5,Feed reheat piping water-2 Visual At three spots on downcomers, ,Suction Examinatio each piping -18 feedwater manifold-3, CC n Nos piping, CC pump pump suction discharge-6 manifold & ,Eco links- 6 discharge piping, 42 locations 18 spots Economiser Boiler Expansion Visual Examinatio n
MS-6,HRHMS-6,HRHMS-6,HRH14,CRH-5,Feed 14,CRHMS-6,HRH14,CRH-5,Feed water-2 5,Feed water-2 14,CRH-5,Feed water-2 ,Suction ,Suction water-2 ,Suction ,Suction manifold-3, CC manifold-3, CC manifold-3, CC manifold-3, CC pump pump pump dischargepump dischargedischarge-6 discharge-6 6 ,Eco links- 6 6 ,Eco links- 6 ,Eco links- 6 ,Eco links- 6 42 spots 42 welds 42 welds 42 welds
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METALLOGRAPHIC EXAMINATION & ME&H THICKNESS MEASUREMENT TM DYE-PENETRANT TESTING DPT MAGENETIC PARTICLE INSPECTION MPI WET FLOURSCENT MAGNETIC FMPI PARTICLE INSPECTION ULTRASONIC TESTING UT RADIOGRPAHIC TESTING RT FIBRO SCOPE TESTING FB DEPOSIT ANALYSIS 23 May 2012 PMI RevisionDA 00
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THANK YOU
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