Soot Blower Erosion

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.

Probable Root Cause

Improper location, operation or malfunction of soot blower Condensed water in media with ash particles
Dr V T Sathyanathan, M.E., Ph.D.

Coal Particle Erosion

Typical Locations
Cyclone type coal burners with introduction of combustion air tangential to tube surface

Corrective Action
Surveillance checks Adjustment of dampers

Probable Root Cause

Wear protection devices inside the burner not performing

Dr V T Sathyanathan, M.E., Ph.D.

Dew Point Corrosion

Typical Locations
Eco, LTSH at regions of :
Metal temp. below acid dew point Flue gas temp. below acid dew point

Corrective Action
Reduce SO3 by reducing excess air (< 5%) and with fuel additives (MgO based) Raise Gas / Metal temperature

Probable Root Cause

Condensation of sulphuric acid - More in oil fired
S in oil Va in oil ash

Dr V T Sathyanathan, M.E., Ph.D.

LOW TEMPERATURE CORROSION

Dr V T Sathyanathan, M.E., Ph.D.

Water Wall Fire-side Corrosion

Typical Locations
WW at :
Incomplete combustion/ reducing atmosphere zones Corrosive ash deposits Flame impingement zones

Corrective Action
Short Term Control :
Operating conditions Burner alignment Higher coal fineness Metal spraying Bleeding air into side wall

Probable Root Cause

Corrosive conditions : inadequate oxygen supply High S & Cl- in fuel Improper burner alignment Molten ash settling

Long Term :
Furnace Modification Surface modified tubing

Dr V T Sathyanathan, M.E., Ph.D.

Waterwall Fire side Corrosion

Dr V T Sathyanathan, M.E., Ph.D.

Dr V T Sathyanathan, M.E., Ph.D.

Dr V T Sathyanathan, M.E., Ph.D.

Dr V T Sathyanathan, M.E., Ph.D.

High Temperature Coal Ash Corrosion

Typical Locations
SH, RH at :
tube surface metal temperature of 590-700 C (Peak at 650C) i.e., radiant zone Slag type corrosive ash deposits adherentto tube Probable Root Cause complex alkali iron trisulphates molten ash corrosive (corrosion at the rate of >0.025m/hour)

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

Dr V T Sathyanathan, M.E., Ph.D.

High Temperature coal Ash Corrosion

As received

Pickled
Dr V T Sathyanathan, M.E., Ph.D.

Sand blasted

Dr V T Sathyanathan, M.E., Ph.D.

High Temperature Coal Ash Corrosion

Dr V T Sathyanathan, M.E., Ph.D.

Dr V T Sathyanathan, M.E., Ph.D.

Dr V T Sathyanathan, M.E., Ph.D.

High Temperature Oil Ash Corrosion

Typical Locations

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

Probable Root Cause

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)

Dr V T Sathyanathan, M.E., Ph.D.

Dr V T Sathyanathan, M.E., Ph.D.

COAL ASH CORROSION OIL ASH CORROSION EXTERNAL PITTING IMPROPER STORAGE LOW TEMPERATURE CORROSION

Dr V T Sathyanathan, M.E., Ph.D.

Dr V T Sathyanathan, M.E., Ph.D.

Dr V T Sathyanathan, M.E., Ph.D.

Maintenance Cleaning Damage

Typical Locations
Regions requiring hammering, chipping, dynamiting, Grit / vacuum blasting

Corrective Action
Repair of damage Documentation of damage left as such Quality Control and Training

Probable Root Cause

Lack of Quality Control during such operations

Dr V T Sathyanathan, M.E., Ph.D.

Chemical Excursion Damage

Typical Locations
Regions not completely neutralised after chemical cleaning Inadvertent exposure to chemical cleaning solutions / corrosive chemicals in the Plant

Corrective Action
Replacement Preventive actions Water Quality Audits

Probable Root Cause

Lack of Quality Control when using corrosive chemicals Malfunction of water chemistry control
Dr V T Sathyanathan, M.E., Ph.D.

Dr V T Sathyanathan, M.E., Ph.D.

Corrosion Attack Due Improper Chemical Cleaning

Dr V T Sathyanathan, M.E., Ph.D.

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

Probable Root Cause

Making of steel, tube Fabrication of tube Storage Erection of Boiler Replacement of tube
Dr V T Sathyanathan, M.E., Ph.D.

INCORRECT MATERIAL TUBE MANUFACTURING DEFECT - FOLD TUBE MANUFACTURING DEFECT - SEAM TUBE BENDING CRACK STRIP HEATED BEND

Dr V T Sathyanathan, M.E., Ph.D.

Dr V T Sathyanathan, M.E., Ph.D.

Dr V T Sathyanathan, M.E., Ph.D.

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

Probable Root Cause

Excess Penetration Porosity, Inclusions Incomplete Fusion Undercut, Pasty Weld Improper Joint Preparation Incorrect Electrode Inadequate Preheat Copper Cracking Weld debris blockage Graphitisation Dr V T Sathyanathan, M.E., Ph.D.

INDUCTION PRESURE WELD PASTY JOINT

Dr V T Sathyanathan, M.E., Ph.D.

SIDE WALL LACK OF FUSION

Dr V T Sathyanathan, M.E., Ph.D.

START STOP GAP IN PULSED MAG WELDING BURN-THROUGH IN SMAW

Dr V T Sathyanathan, M.E., Ph.D.

Dr V T Sathyanathan, M.E., Ph.D.

TRANSPORTATION DAMAGE AT WIRE LASHING REGION

Dr V T Sathyanathan, M.E., Ph.D.

LIGAMENT CRACKING IN HEADER

Dr V T Sathyanathan, M.E., Ph.D.

CREEP FAILURE OF A LINK PIPE IMPROPER SUPPORT

Dr V T Sathyanathan, M.E., Ph.D.

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

Dr V T Sathyanathan, M.E., Ph.D.

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

Dr V T Sathyanathan, M.E., Ph.D.

IMPACT OF INDIAN COALS ON TUBE FAILURES

Dr V T Sathyanathan, M.E., Ph.D.

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

Dr V T Sathyanathan, M.E., Ph.D.

COAL / ASH HANDLED

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

ASH PRODUCED t/h

Dr V T Sathyanathan, M.E., Ph.D.

INDIAN COAL Vs USA COAL

PARAMETER HEAT DUTY FUEL FIRED HHV QUANTITY OF FUEL AVERAGE ASH CONTENT QUANITY OF ASH mcal/h. kcal/kg. t/h. % t/h. INDIAN UNIT 210 MW 500 MW 454 3800 137 40 55 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

Dr V T Sathyanathan, M.E., Ph.D.

Problems Associated With Indian Coals

hDeteriorating heating value of the coal hInconsistent coal properties hPresence of extraneous matters in coal hHigh quantum of ash with high percentage of quartz hHighly abrasive nature of coal ash hDue to low sulphur content extremely high electrical resistivity of ash
Dr V T Sathyanathan, M.E., Ph.D.

MAJOR BOILER TUBE FAILURE IN INDIAN COAL FIRED BOILERS

STRESS RUPTURE
SHORT TERM OVERHEATING HIGH TEMPERATURE CREEP DISSIMILAR METAL WELDS

WATER SIDE CORROSION

CAUSTIC CORROSION HYDROGEN DAMAGE PITTING (LOCALISED CORROSION)

FATIGUE
THERMAL
Dr V T Sathyanathan, M.E., Ph.D.

MAJOR BOILER TUBE FAILURE IN INDIAN COAL FIRED BOILERS (CONTD..)

EROSION
FLY ASH EROSION FALLING SLAG EROSION SOOT BLOWING EROSION COAL PARTICLE EROSION

LACK OF QUALITY CONTROL

CHEMICAL EXCURSION DAMAGE WELDING DEFECTS

Dr V T Sathyanathan, M.E., Ph.D.

Tube Failures (Areawise)

Reheater 9% Wall RH 2% Economiser 16%

Tube Failures (Causewise)

Pitting 3% Shop Weld 6%

Steam Erosion 6% Overheating 9%

Site Weld 16%

LTSH 16%

Ceiling SH 1%

Mech.Rubbing 5%

Matl. mix-up 3%

Platen SH 6%

SCW 15%

Div.Panel 2%

Attac h .We ld 20%

Ash Erosion 28%

Waterwall 33%
P.F.Erosion 4%

Factors Influencing Ash Erosion In Coal Fired Boilers

The velocity of flue gas The mineral content in coal The change in direction of flue gas The arrangement of pressure parts The temperature of flue gas Bypassing of flue gas
Dr V T Sathyanathan, M.E., Ph.D.

Flue Gas Velocity- Erosion

Earlier BHEL adopted 12 - 13 m/sec in second pass Presently 10 - 11 m/sec further reduction to 9 - 10 m/sec. Very low velocity in second pass leads to settling etc. Rate of erosion increases by power 3 to 5. Power depends on alpha quartz and structure of quartz.
Dr V T Sathyanathan, M.E., Ph.D.

Determination Of Velocity Pattern

Cold air velocity mapping Flow model study

Dr V T Sathyanathan, M.E., Ph.D.

Cold Air Velocity Mapping

Done in actual boiler Maximum flow maintained Grid method used Vane anemometer used for finding the velocity Identify high velocity points Check for erosion potential etc. Identify reasons
Dr V T Sathyanathan, M.E., Ph.D.

Flow Model Study

1:10 model used Dynamic similarity maintained Flow velocity measured at each section High velocity points identified Study with different arrangement possible Flow correction is possible
Dr V T Sathyanathan, M.E., Ph.D.

Dr V T Sathyanathan, M.E., Ph.D.

ANOTHER VIEW OF THE FLOW MODEL

Dr V T Sathyanathan, M.E., Ph.D.

Reasons For Moderate Flue Gas Velocity

To reduce erosion in second pass To avoid ash settling To effect heat transfer

Dr V T Sathyanathan, M.E., Ph.D.

CONVENTIONAL BOILER

TOWER TYPE BOILER

Dr V T Sathyanathan, M.E., Ph.D.

STAGGERED ARRANGEMENT
DIRECTION OF GAS FLOW

TUBE

Dr V T Sathyanathan, M.E., Ph.D.

INLINE ARRANGEMENT
DIRECTION OF FLUE GAS

TUBE

Dr V T Sathyanathan, M.E., Ph.D.

Temperature Of Flue Gas

Furnace zone (high temp.) Ash is soft As temperature reduces ash become abrasive 650-700c Lower temperature like 350-400c ash is highly abrasive Practically also seen
Dr V T Sathyanathan, M.E., Ph.D.

EROSION PROTECTION METHODS

CASSETTE BAFFLES STRAIGHT TUBE SHIELDS

Dr V T Sathyanathan, M.E., Ph.D.

MEASURES BY BHEL TO REDUCE EROSION FAILURES

Reduced gas velocity in second pass Inline arrangement for LTSH and ECO. Shielding of places prone for high erosion. Cassette baffles for LTSH and Eco. Bends. Refractory lining in high erosion areas where shields can not be provided. Pressure part layout improvement in second pass
Dr V T Sathyanathan, M.E., Ph.D.

Design Improvements for Reduced Tube Failure

Lower flue gas velocity over tube banks Plain tube in-line arrangement of heat transfer surface Optimum end caps to avoid preferential gas flow Erosion shields / cassette baffles Erosion allowance for leading tubes
Dr V T Sathyanathan, M.E., Ph.D.

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
Dr V T Sathyanathan, M.E., Ph.D.

ANY QUESTIONS PLEASE

Dr V T Sathyanathan, M.E., Ph.D.

Thank You All

Dr V T Sathyanathan, M.E., Ph.D.