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P Nagamanickam

MATERIAL DAMAGE MECHANISMS AND RLA OF BOILERS

BHEL, Tiruchirappalli 620014

P Nagamanickam

P Nagamanickam

Improved Availability/ Reliability

Reducing boiler outage occurrences pressure part failures & other causes (increasing MTBF) Reducing forced outage duration on account of boiler pressure part failures + other causes (reducing MTTR) Reducing occurrences of partial outage - (restricted loading) of boilers Reducing the duration of operation under partial outage mode
P Nagamanickam

Boiler Tube Failures

Boiler Tube Failures - main cause of

forced outages in electric utility steam generating boilers

Single tube Failure in a 500 MW Rs. 5

to 6 Crores (replacement power charges for 3-4 days to repair) besides affecting Plant Morale.

P Nagamanickam

Boiler Tube Failures (22 Primary Mechanisms)

Stress Rupture
Short Term Overheating High Temperature Creep Dissimilar Metal Welds

Fatigue
Vibration Thermal Corrosion

Water-side Corrosion
Caustic Corrosion Hydrogen Damage Pitting Stress Corrosion Cracking Low Temperature Waterwall - 6 Coal Ash - 6 Oil Ash

Erosion
Fly Ash Falling Slag Soot Blower Coal Particle

Fire-side Corrosion

Lack of Quality Control

Maintenancecleaning damage Chemical excursion damage Material Defects Welding Defects

6 - indicates that such problems have not been reported in India

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LONG TERM OVERHEATING OVERHEATING, CREEP INCORRECT MATERIAL OVERHEATING BULGING, SATELLITE SCALE CRACKING OVERHEATING WATERSIDE DEPOSITS

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Tube Failures (Areawise)

Reheater 9% Wall RH 2% Economi ser 16% Ceiling SH 1%

Tube Failures (Causewise)

Steam ErosionPitting 3% 6% Shop Weld 6% Site Weld 16%

Overheatin g 9% Mech.Rub bing 5%

LTSH 16%

Platen SH 6%

SCW 15%

Matl. mixup 3%

Div.Panel 2% Waterwall 33%

Attach.W eld 20% P.F.Erosi on 4% Ash Erosion 28%

Based on NTPC 500 MW boiler tube failure data

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Design Improvements for Reduced Tube Failure

Lower flue gas velocity over tube banks Plain tube in-line arrangement of heat transfer surface Optimum end gaps to avoid preferential gas flow Erosion shields / cassette baffles Erosion allowance for leading tubes
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Design Improvements for Reduced Tube Failure (Cont)

Higher flexibility in SH / RH nipples Redesigned flexible connectors for pendant type SH coils Improved supports for LTSH / Eco. Coils Improved seal plate connection for bottom hopper Modified LTSH inlet tube connection
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Impact Of Indian Coals On Tube Failures & Design Improvements for Tube Failure Reduction
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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

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COAL / ASH HANDLED

HHV UNIT RATING ASH FUEL FIRED kcal/kg mw % t/h 4750 210 28 110 30.8 500 28 272 76.2 210 30 129 38.7 4050 500 30 319 95.7 210 45 174 78.3 3000 500 45 430 193.5

ASH PRODUCED t/h

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INDIAN COAL Vs USA COAL

PARAMETER HEAT DUTY FUEL FIRED HHV QUANTITY OF FUEL AVERAGE ASH CONTENT QUANITY OF ASH mcal/h. INDIAN UNIT 210 MW 500 MW 454 1070 1215 3800 320 40 128 USA UNIT 210 MW 500MW 454 520 6000 87 8 7 1070 1215 6000 202.5 8 16.2

mkcal/h. 520 kcal/kg. t/h. % t/h. 3800 137 40 55

P Nagamanickam

Problems Associated With Indian Coals

h Deteriorating heating value of the coal h Inconsistent coal properties h Presence of extraneous matters in coal h High quantum of ash with high

percentage of quartz

h Highly abrasive nature of coal ash h Due to low sulphur content extremely

high electrical resistivity of ash creates problems in ESP.

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Current trends in Remaining Life Prediction

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Residual Life Assessment Study

RLA study conducted to find out: The present condition of the boiler pressure parts To assess the remaining life

P Nagamanickam

Various modules of a typical R&M Project

Design Review Operational History Review

Residual Life Assessment Pressure Parts

Condition Assessment Non-Pressure Parts

Performance Eevaluation Test

Identification of Critical Components R&M Proposal

Identification of System Limitations

Feedback

Single Phase R&M

Multi-Phase R&M

Performance Evaluation

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Why RLA Study

Ageing of boilers consequent to creep / fatigue stresses in pressure parts of boiler

Material degradation

due to corrosion, erosion and oxidation

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Run

Repair

Replace

RLA

Evaluates For All Phases

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Why RLA Study

Operation of boiler at elevated

temperatures more than design limit Variations in coal quality Deviations in Water Chemistry

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Why RLA Study

Erosion on on the outer surface of the drum due to steam leakage

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Why RLA Study

Sagged Header

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Foreign Body inside RH Inlet Header

Why RLA Study

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Seawater Corrosion in S-Panel

Why RLA Study

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RLA Study Aims At

l

Evaluation of present condition of pressure parts & piping Avoiding premature pressure parts failures and associated unforeseen outages Identification of problem areas Analysis of root cause of problems Estimation of balance life of pressure parts Providing technically sound and viable proposal for implementation
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RLA of What?
Pressure parts Highly varying duty
Varying Load, Cyclic Load Temperature Excursions Fuel Quality Variations

Carried out extensively Structural parts Limited study Need based Visual examination gives good clue Non pressure parts Mostly maintenance oriented Can be assessed easily
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Steam Generating Unit

Pressure Parts

High Temperature High Pressure Parts Superheater Reheater

Low Temperature High Pressure Parts LTSH, Economiser Waterwall, Boiler Drum, Headers
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Critical Piping MS Line CRH & HRH Lines

Stages of Residual Life Assessment

Review of past operational &

maintenance data of the plant including water chemistry variations Field testing Laboratory testing

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Review Of Past Data

Plant operation
Number of start-ups downs Operating conditions Operating practice & shut

Maintenance and repair

Failures and repairs Review of root cause analysis Details of modifications

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Field Testing
Visual inspection Erosion, corrosion Swelling, scaling Deposits, misalignments Supports, pipe hangers etc Dimensional checks Thickness Diameter
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Field Testing
Non destructive examination
Penetrant testing including fluorescent type Magnetic particle inspection (Wet fluorescent & Dry) Ultrasonic testing In-situ hardness checks Eddy current testing

Tube sampling - WW internal deposits In-situ Hydrogen embrittlement inspection

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Field Testing
In-situ Alloy Analysis In-situ Oxide Scale Thickness measurement In-situ metallographic examination Fiberscopic/Videoscopic inspection

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Typical Tests Done for RLA

High temperature piping headers &
Ultrasonic, dye-penetrant tests Fiberscopy, replication Other inspections like
Dimensions, Internal inspection In-situ hardness

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Typical Tests Done for RLA

Superheater & Reheater tubes
Tube samples OD & Thickness Steam side oxide scale thickness Metallurgical analysis NDT of DMW joints

Attemperators
Ultrasonic, dye penetrant tests Replication, hardness Fiberscopy

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Typical Tests Done for RLA

Drums & downcomers
Ultrasonic, dye-penetrant tests MPI (Wet fluorescent & Dry) Fiberscopy

Furnace & convection pass tubes

Tube samples Deposit analysis (Internal & External)

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Steam Piping
Visual Inspection Replication, In-situ Hardness measurement OD & thickness Hangers & Supports Inspection Stress analysis to identify the most stressed points

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Waterwall Tubes
Tubes samples from high heat flux zone
Detailed dimensional measurements Metallurgical analysis Presence of internal deposits covering
Deposit content Constituents of deposit Solvent selection if cleaning is necessary

Presence of external and internal corrosion Micro structure analysis (hydrogen damage)

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General guidelines for selecting inspection points

High turbulence or velocity zones Condensation points Dead ends & high stressed points Areas immediately downstream of chemical injection points All supports

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Laboratory Testing
Microscopic examination (Light Microscopy & SEM) Deposit analysis External) ( Internal &

Accelerated creep rupture testing Other mechanical & metallurgical tests

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Scope of RLA as per IBR 391 A

Component Drum (Steam) Water Drum Low Temp header Attemperator Header High Temp Header Low temp eco tubes Convection SH coils Primary SH coils Prefinal SH coils Final SH Coils Reheater coils High temp header Final SH header Reheater Header Main steam piping Platen SH header Primary SH header Economizer header Auxiliaries Boiler bank tubes Water wall Furnace water walls Ultrasonic Visual testing Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 'Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No Yes No No No No No No No Yes Yes Yes No *** Yes Yes No No No No No Magnetic Liquid/Dye particel penetrant Deposit testing inspection Replication Sampling Analysis No No No No No No No * * * * * * * Yes Yes Yes Yes No No No No No No No Yes Yes Yes No Yes Yes Yes No No No No Yes Yes No Yes No No No No No No No Yes Yes Yes Yes Yes Yes No No No No No No No No No Yes Yes Yes Yes Yes Yes Yes No No No No No No No No No Yes Yes Yes Yes No No No No Yes No No No No No No No No No No No No No No No

No * No * No * No No No No No No No No No No No No * * * * * * * * * * * *

* MPI will be done on case to case basis ** Oxide scale based life prediction will be done based on operational history and failures *** UT for checking integrity of butt welds $ Header internal inspection by fiberscope

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Microstructural Evaluation By Replication

Sampling thick walled components is not possible Non-destructive technique adopted for evaluation is replication. To examine spheroidisation and cavitation level

P Nagamanickam

Replica Technique
The material surface preparation by grinding, polishing and etching The plasticised replica is applied firmly to the surface After curing, the replica can be removed and gold sputtered & the topographical image of the micro structure is examined

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Replica Technique

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Gold Sputtered Replica

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Creep Cavity Level Classification System Proposed by Wedel & Neubauer

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Life Prediction Techniques

Post exposure creep testing Using Steam thickness By using parameter Side Oxide scale

appropriate

damage

Using strain measurements

History based computation

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Metallographic Method
A = 1 - ( 1 - t/Tr )( -1)/n
= Nd
N d + Nu Nd= Number of damaged grain boundaries Nu= Number of undamaged grain boundaries T= Time in service at the time of examination Tr= Time of rupture = Material constant

A = damage parameter

(Tr - t) =

RESIDUAL LIFE

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Strain Measurement Method

LOG (1- t1/tr) = ( E1 / E2 ) LOG (1-t2/tR)
E1 E2 tR = = = Strain at time t1 Strain at time t2 Time to rupture PIP

(tR - t2) = (t2-t1)

Residual life

= Must be 10,000 hrs minimum

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Post Exposure Testing

Life fraction rule
{( ts /Ts ) + ( tt /Tt )} = 1
tS= Time in service TS= Rupture time under service conditions tt= Rupture time in the accelerated test of service sample Tt= Rupture time of the new (virgin) material under accelerated conditions

( TS - tS ) = Remaining life
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Oxide Scale Thickness Analysis

Steam side oxide scale measured from sample / site Tube dimension Master creep rupture data for the material concerned From the above we can calculate the remaining life of the tube.
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Oxide Scale Thickness Analysis

Steam side scale thickness is related to wall temperature as
LOG X = 0.00022(T+460)(20+log t) - 7.25
X= Steam side oxide scale thickness in mills t = Service hours T = Metal temperature ( F )

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Codes & Standards to which work executed

Indian Boiler Regulations ASME BS ANSI DIN

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Unique Test Facilities at BHEL

Post exposure Uni-Axial Accelerated creep testing In-situ Hardness Tester In-situ Polishing Equipment for Replica Sampling Digital Strain Measurement Gauge Portable Microscope for In-situ Metallurgical Examination Portable Alloy Analyzer 100 T Static dynamic MTS tensile testing machine with microprocessor
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Unique Test Facilities at BHEL

Impact test facility up to minus 196 C Vacuum Emission Spectrometer Scanning Electron Microscope Atomic Absorption Spectrometer Portable Stress Analyzer Videoscope
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Scanning Electron Microscope

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Special NDT Techniques Developed by BHEL

Detection of hydrogen damage by UT Measurement of oxide scale thickness by UT. Microstructural evaluation by replication A new technique called VAPINE'. Detection of ligament cracks in headers by UT.
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In-situ Hydrogen Damage Detection

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Ligament Crack Detection by UT

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Typical Recommendations
Residual life / inspection intervals of components Parts needing replacements Parts needing repairs Chemical cleaning advice & procedure Modifications required for life extension

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Typical Recommendations
Advice on water regimes Improvements in operational methods Future plans of tests Retrofits / improvements in control & instrumentation Any other specific observations
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RLAs carried out by BHEL

Total Studies Carried Out BHEL Boilers 176 090

Non- BHEL Boilers 086 In India Abroad 165 011

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Case Studies

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CASE STUDY I
Boiler Details Evaporation capacity : 75 tons/hr Design pressure : 39 kg/ sq. cm Design Temperature : 440 C Type : Non reheat / Balanced
Design )

draft ( Russian

Material used Service Hours

Steel 20 ( Equivalent to Carbon Steel )

: 150, 000

P Nagamanickam

CASE STUDY I
The study revealed that the condition of boiler drum , water walls and SH coils are good enough for continued operation. The secondary superheater outlet header when examined with fibroscope indicated presence of ligament cracks in longitudinal section . Few ligaments on the left extreme were only found to have cracks where as the other ligaments were found to be having just initiation of cracks. It was decided to partly remove the left extreme portion of the header which had cracks in ligaments beyond acceptable level and start the unit.
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CASE STUDY I
The removed portion of header material was analysed in Laboratory and the lab analysis indicated that the ligament crack was due to corrosion fatigue.

P Nagamanickam

CASE STUDY I
The remaining life assessment study carried in the above unit indicated the possibility for continued operation with the existing components and it was necessary only to replace part of SH assemblies and the secondary SH outlet header with a new header .

P Nagamanickam

CASE STUDY II
A 140 MW reheat , balanced draft type unit was taken up for study after a service period of 130,000 hours The work scope for remaining life assessment study covered the following.
Detection of hydrogen damage in water walls using attenuation principle. Inspection of cold reheat & hot reheat header internals by using fibroscope and also by ultrasonic testing . Replication at high temperature locations for evaluation of micro structural degradation. Inspection of desuperheater nozzle and liner. Sampling from different locations of SH & RH for metallurgical analysis.

P Nagamanickam

CASE STUDY II
The major findings study are given below:

from the

Boiler drum Good condition. Furnace tubes No hydrogen damage. Economiser, Primary SH & Conv.SH coils Adequate remaining life . Reheater Misalignment of coils and low remaining life Cold RH Header Erosion in stub bends Hot reheat header Ligament cracks particularly near the T piece. Desuperheater Enlargement of nozzle hole and also cracks in the liner plates. Piping No microstructure degradation

P Nagamanickam

CASE STUDY II
The HR header inside surface was checked using fiberscope and cracks were seen in circumferential ligaments particularly near T piece The other ligament locations were found to be free from service cracks. The replica taken covering the weld and the heat affected zone location of the reheat outlet header revealed that the header material had not undergone any micro structural degradation. The decision to continue to operate with existing cracks in the ligament location adjacent to the T piece was carefully done after evaluation of the crack size and taking into consideration the duration required for arranging replacement.
P Nagamanickam

CASE STUDY II
Thus with the remaining life assessment study done in this unit, the utility could plan for life extension and the life extension program for this unit could be done only by part replacement of specific components as identified above thereby the investment required for life extension program could be minimised.
P Nagamanickam

CASE STUDY III

VU40, 275 t/hr., 95 kg/cm2 , 530 deg.C. SSH 47 assemblies, dia 51x4.5, 7.1mm, material: T1, T11, T22 and TP 347 H. Commissioned in 1981. 1,12,000 hrs. Tube failure started in SSH in April 2001. The failures confined to outlet section of SA 213 T22 and SA 213 TP 347H material. The failures were mainly due to creep.
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CASE STUDY III

RLA carried out in May 2001. All areas found to be healthy except SSH . IOT, Tube sample analysis & CRT for SSH. Tube sample analysis indicated SL IV, polygonal grains of F and completely spheroidised C. Oxide scale measured to the level of 0.916mm indicating overheating of the tubes above design temperature. CRT indicated higher life and tube sample taken might not have been representative.
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CASE STUDY III

RLA indicated creep in SSH and material degradation. The micro analysis revealed presence of numerous creep cavities in the grain boundary of the material in both TP 347 H and T 22. Recommendation given for the replacement of SSH coils of entire T 22 and TP 347 H portions.
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CASE STUDY III

Reasons for the overheating identified and corrective measures given as below: Overloading / over firing of the boiler beyond the rated capacity should be avoided. Measures to maintain the temp.within limits. Higher start-up rate of the boiler to be avoided. Continuous monitoring of the metal temperature of SSH shall be carried out.
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CASE STUDY IV
120 MW, 383 t/hr., 134 kg/cm2 and 540 deg. C. Boiler commissioned in 1976, 1,55,000hrs. RLA study was conducted by other agency in 1995 (Electrim) and boiler was given fit. RLA by BHEL was carried out in April 2003. All components found fit except for main steam line T joint, PRDS piping and reheat piping which have shown degradation due to creep.
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P Nagamanickam

CASE STUDY IV
Main steam line had a crack to a length of 40 to 48mm and to a depth of 12 to 20 mm at the T piece. This crack was identified through UT. This crack was seen in all three welds of the cast `T. Material BS 3604 HFS 660. The cracks were confined to the weld location. Metallurgical replication and hardness testing also carried out.

P Nagamanickam

CASE STUDY IV
Cast Tee : CSN 422744.1 , diameter 323.9x42 at the connecting ends of reducers Reducer : BS 3604 HFS 660, 323.9x42 at the connecting ends of `T. Replica Analysis confirmed that the T piece and the main steam line have degraded to SL V and isolated creep pores observed. Repair procedure given for re-welding the joints after removal of cracks. Recommended for replacement of T piece, main steam piping , PRDS piping and reheat piping in 3 years.
P Nagamanickam

CASE STUDY IV
Recommended for replacement of T piece, main steam piping , PRDS piping and reheat piping. Unit 1 RLA in OCT 2003 also revealed Cracks in T, PRDS piping and RH piping. It is decided to Focus on all old projects where ever similar materials and welds are made to look for this problem.
P Nagamanickam

Case Study V
NTPC, Korba STPS., Unit-2, 200 MW, 670 T/Hr, 154.9 Kg/cm2 and 540 deg. C. Boiler commissioned in 1983,1,14,000hrs. RLA by BHEL was carried out in April 1999. The Boiler was found fit for continued operation and some high temperature components were found to have creep pores and re-inspection recommended.
P Nagamanickam

Component: Steam Drum Recommendation: Fit for Continued Operation Re-Examination After 5 Years Basis for Recommendation Visual Inspection NDT Checks Replication
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Component: Water Walls Recommendation: Fit for Continued Operation Tube Deposit Analysis By Sampling in the Next Overhaul Basis for Recommendation Internal Deposit Content Shows Moderately Dirty Condition
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Component: Eco Coils Recommendation: Fit for Continued Operation Re-Examination After 5 Years Basis for Recommendation Visual Inspection , Thickness Survey & Metallurgical Analysis of Tube Samples

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Component:LTSH Coils & Terminal Tubes Recommendation: Fit for Continued Operation Re-Examination After 5 Years Basis for Recommendation Visual Inspection , Thickness Measurement ,Metallurgical Analysis by Tube Sampling

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Component: Final SH Coils Recommendation: Tube Sample Analysis After 20,000 Hrs of Continued Operation Basis for Recommendation Visual Inspection Metallurgical Analysis Oxide Scale Thickness Measurement
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Component: Screen Tubes Recommendation: Fit for Continued Operation Re-Examination After 5 Years Basis for Recommendation Visual Inspection Thickness Survey

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Component: Extended SCW Recommendation: Fit for Continued Operation Re-Examination After 5 Years Basis for Recommendation Visual Inspection

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Component: RH Coils Recommendation: Fit for Continued Operation Re-Examination After 5 Years Basis for Recommendation Visual Inspection Dimensional Measurement Metallurgical Analysis Oxide Scale Thickness Measurement
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Component: Platen SH Coils Recommendation: Fit for Continued Operation Re-Examination After 5 Years Basis for Recommendation Visual Inspection Dimensional Measurement Metallurgical Analysis Oxide Scale Thickness Measurement

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Component: Economiser Headers Recommendation: Fit for Continued Operation Re-Examination After 5 Years Basis for Recommendation Visual Inspection Dimensional Measurement

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Component: LTSH Headers Recommendation: Fit for Continued Operation Re-Examination of inlet header after 5 Years Re-Examination for Outlet Header After 2 Years Basis for Recommendation Visual Inspection Dimensional Measurement Replica Analysis Fibroscopic Inspection
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Component: DESH Headers Recommendation: Re-Examination After 2 Years of Continued Operation Basis for Recommendation Visual Inspection Dimensional Measurement Ndt Tests Replica Analysis Fibroscopic Inspection
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Component: Platen SH Headers Recommendation: Inlet Header Is Fit for Continued Operation and Re-Examination After 5 Years Re-Examination for Outlet Header After 2 Years Basis for Recommendation Visual Inspection NDT Tests Dimensional Measurement Replica Analysis Fibroscopic Inspection
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Component: Final SH Headers Recommendation: Fit for Continued Operation Re-Examination After 2 Years of Continued Operation Basis for Recommendation Visual Inspection Dimensional Measurement Replica Analysis Fibroscopic Inspection NDT Tests
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Component: Reheater Headers Recommendation: Fit for Continued Operation Re-Examination After 2 Years of Continued Operation Basis for Recommendation Visual Inspection Dimensional Measurement Replica Analysis Fibroscopic Inspection NDT Tests
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Component: WW Headers Recommendation: Fit for Continued Operation Re-Examination After 5 Years Basis for Recommendation Visual Inspection Fibroscopic Inspection

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Component: Main Steam Line Recommendation: Fit for Continued Operation Re-Examination After 2 Years of Continued Operation Basis for Recommendation Visual Inspection Dimensional Measurement Replica Analysis NDT Tests
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Component: Hot Reheat Piping Recommendation: Fit for Continued Operation Re-Examination After 2 Years of Continued Operation Basis for Recommendation Visual Inspection Dimensional Measurement Replica Analysis NDT Tests
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Component: Cold Reheat Piping Recommendation: Fit for Continued Operation Re-Examination After 5 Years of Continued Operation Basis for Recommendation Visual Inspection Dimensional Measurement

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Component: PRDS Piping Recommendation: Fit for Continued Operation Re-Examination After 5 Years of Continued Operation Basis for Recommendation Visual Inspection Dimensional Measurement

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Component: Hangers Recommendation: Fit for Continued Operation Basis for Recommendation Visual Inspection

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Component: Pipings Recommendation: Fit for Continued Operation Basis for Recommendation Visual Inspection Component:Safety Valves Recommendation: Fit for Continued Operation Basis for Recommendation Visual Inspection

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ANY QUESTIONS PLEASE

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Thank You

P Nagamanickam