Professional Documents
Culture Documents
Soot Blower Erosion: Typical Locations Corrective Action
Soot Blower Erosion: Typical Locations Corrective Action
Typical Locations
Wall blower steam impingement areas First tubes near wall entrance of retractable blowers Near damaged soot blower nozzle Direct path of soot blowers
Corrective Action
Surveillance and maintenance of soot blower system Temporary shielding, spaying etc.
Corrective Action
Surveillance checks Adjustment of dampers
Corrective Action
Reduce SO3 by reducing excess air (< 5%) and with fuel additives (MgO based) Raise Gas / Metal temperature
Corrective Action
Short Term Control :
Operating conditions Burner alignment Higher coal fineness Metal spraying Bleeding air into side wall
Long Term :
Furnace Modification Surface modified tubing
Corrective Action
Thicker, shielded tubes Thermal spraying Higher grade alloy Blending the coal Lower metal temperature at steam outlet Redesign of tubing circuits
Corrosive conditions
As received
Pickled
Dr V T Sathyanathan, M.E., Ph.D.
Sand blasted
Corrective Action
Thicker, shielded tubes Thermal spraying Higher grade alloy Injecting oil additive (MgO based) RLA of tubes Control of excess air
SH, RH at :
Tube surface metal temperature of >593C . Corrosive ash deposits adherent to tube with V, S and Na
Corrosive conditions :
Complex sodium vanadium compound in molten ash Greatest wastage is when sodium oxide to vanadium oxide ratio is 1:5 (corrosion at the rate of >0.025m/hour)
COAL ASH CORROSION OIL ASH CORROSION EXTERNAL PITTING IMPROPER STORAGE LOW TEMPERATURE CORROSION
Corrective Action
Repair of damage Documentation of damage left as such Quality Control and Training
Corrective Action
Replacement Preventive actions Water Quality Audits
Material Defects
Typical Locations
Could occur at any location but more likely at high temperature zones because of stress rupture mechanisms (350 km of tubing for a 500 MW Boiler)
Corrective Action
Replacement Preventive Actions
INCORRECT MATERIAL TUBE MANUFACTURING DEFECT - FOLD TUBE MANUFACTURING DEFECT - SEAM TUBE BENDING CRACK STRIP HEATED BEND
Welding Defects
Typical Locations
Could occur at any location where tubing is joined (58000 Butt Welds for a 500 MW Boiler, besides several km of fillet welds) Processes used : SMAW, GTAW, Pulsed MAG, Orbital TIG, Induction Pressure Flash Butt Welding
Corrective Action
Replacement Preventive Actions Process Controls
Some of the problem areas to look for in High Temperature Headers, Steam Pipes
Graphitisation of Carbon and Carbon -Molybdenum Pipes at service above 427C and 468C respectively Header Drain Stub Cracking by Thermal fatigue Ligament Cracks in Headers SH Inlet Header (Inside surface) Erosion by down stream spray water Creep-Fatigue cracks in circumferential pipe butt welds and Header Tee welds due to bending stresses, lack of flexibility, supports problem, header movement etc. Long Seam welds of Hot Reheat Pipes - Creep cracks - indicates that such problems have not been reported in India
Some of the problem areas to look for in High Temperature Headers, Steam Pipes (Cont)
Header Stub Cracking by Creep-Fatigue Header, Pipe to Flat end cap weld - Fatigue / Thermal Fatigue cracks at ID counter-bore, odd weld root, drain holes located in weld Creep Cracks in weld-fabricated Tees or Cast Tees at or near branch welds Localised creep crack in long link pipes in the pent house, not properly supported because of bending stresses (in carbon steel at 370C) - indicates that such problems have not been reported in India
DETERIORATION OF COAL QUALITY AVAILABLE FOR POWER GENERATION OVER THE PERIOD
1970s PROXIMATE ANALYSIS FIXED CARBON VOLATILE MATTER MOISTURE ASH HHV HGI % % % % kcal/kg 36.5 25.5 10.0 28.0 4750 50 32.4 21.6 16.0 30.0 4050 50 25.0 18.0 12.0 45.0 3000 50 1989s 1990s
mkcal/h. 520
FATIGUE
THERMAL
Dr V T Sathyanathan, M.E., Ph.D.
LTSH 16%
Ceiling SH 1%
Mech.Rubbing 5%
Matl. mix-up 3%
Platen SH 6%
SCW 15%
Div.Panel 2%
CONVENTIONAL BOILER
STAGGERED ARRANGEMENT
DIRECTION OF GAS FLOW
TUBE
INLINE ARRANGEMENT
DIRECTION OF FLUE GAS
TUBE