Professional Documents
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P Nagamanickam
P Nagamanickam
P Nagamanickam
to 6 Crores (replacement power charges for 3-4 days to repair) besides affecting Plant Morale.
P Nagamanickam
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
P Nagamanickam
P Nagamanickam
P Nagamanickam
LONG TERM OVERHEATING OVERHEATING, CREEP INCORRECT MATERIAL OVERHEATING BULGING, SATELLITE SCALE CRACKING OVERHEATING WATERSIDE DEPOSITS
P Nagamanickam
P Nagamanickam
LTSH 16%
Platen SH 6%
SCW 15%
Matl. mixup 3%
Impact Of Indian Coals On Tube Failures & Design Improvements for Tube Failure Reduction
P Nagamanickam
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
P Nagamanickam
P Nagamanickam
P Nagamanickam
percentage of quartz
h Highly abrasive nature of coal ash h Due to low sulphur content extremely
P Nagamanickam
P Nagamanickam
Feedback
Multi-Phase R&M
Performance Evaluation
P Nagamanickam
Material degradation
P Nagamanickam
Run
Repair
Replace
RLA
temperatures more than design limit Variations in coal quality Deviations in Water Chemistry
P Nagamanickam
Sagged Header
P Nagamanickam
P Nagamanickam
P Nagamanickam
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
P Nagamanickam
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
P Nagamanickam
Low Temperature High Pressure Parts LTSH, Economiser Waterwall, Boiler Drum, Headers
P Nagamanickam
maintenance data of the plant including water chemistry variations Field testing Laboratory testing
P Nagamanickam
P Nagamanickam
Field Testing
Visual inspection Erosion, corrosion Swelling, scaling Deposits, misalignments Supports, pipe hangers etc Dimensional checks Thickness Diameter
P Nagamanickam
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
P Nagamanickam
Field Testing
In-situ Alloy Analysis In-situ Oxide Scale Thickness measurement In-situ metallographic examination Fiberscopic/Videoscopic inspection
P Nagamanickam
P Nagamanickam
P Nagamanickam
Attemperators
Ultrasonic, dye penetrant tests Replication, hardness Fiberscopy
P Nagamanickam
P Nagamanickam
Steam Piping
Visual Inspection Replication, In-situ Hardness measurement OD & thickness Hangers & Supports Inspection Stress analysis to identify the most stressed points
P Nagamanickam
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)
P Nagamanickam
P Nagamanickam
Laboratory Testing
Microscopic examination (Light Microscopy & SEM) Deposit analysis External) ( Internal &
P Nagamanickam
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
P Nagamanickam
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
P Nagamanickam
Replica Technique
P Nagamanickam
P Nagamanickam
P Nagamanickam
appropriate
damage
P Nagamanickam
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
P Nagamanickam
Residual life
P Nagamanickam
( TS - tS ) = Remaining life
P Nagamanickam
P Nagamanickam
P Nagamanickam
P Nagamanickam
P Nagamanickam
Typical Recommendations
Residual life / inspection intervals of components Parts needing replacements Parts needing repairs Chemical cleaning advice & procedure Modifications required for life extension
P Nagamanickam
Typical Recommendations
Advice on water regimes Improvements in operational methods Future plans of tests Retrofits / improvements in control & instrumentation Any other specific observations
P Nagamanickam
P Nagamanickam
Case Studies
P Nagamanickam
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
: 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.
P Nagamanickam
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 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.
P Nagamanickam
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
P Nagamanickam
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
P Nagamanickam
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
P Nagamanickam
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
P Nagamanickam
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
P Nagamanickam
Component: Screen Tubes Recommendation: Fit for Continued Operation Re-Examination After 5 Years Basis for Recommendation Visual Inspection Thickness Survey
P Nagamanickam
Component: Extended SCW Recommendation: Fit for Continued Operation Re-Examination After 5 Years Basis for Recommendation Visual Inspection
P Nagamanickam
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
P Nagamanickam
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
P Nagamanickam
Component: Economiser Headers Recommendation: Fit for Continued Operation Re-Examination After 5 Years Basis for Recommendation Visual Inspection Dimensional Measurement
P Nagamanickam
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
P Nagamanickam
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
P Nagamanickam
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
P Nagamanickam
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
P Nagamanickam
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
P Nagamanickam
Component: WW Headers Recommendation: Fit for Continued Operation Re-Examination After 5 Years Basis for Recommendation Visual Inspection Fibroscopic Inspection
P Nagamanickam
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
P Nagamanickam
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
P Nagamanickam
Component: Cold Reheat Piping Recommendation: Fit for Continued Operation Re-Examination After 5 Years of Continued Operation Basis for Recommendation Visual Inspection Dimensional Measurement
P Nagamanickam
Component: PRDS Piping Recommendation: Fit for Continued Operation Re-Examination After 5 Years of Continued Operation Basis for Recommendation Visual Inspection Dimensional Measurement
P Nagamanickam
Component: Hangers Recommendation: Fit for Continued Operation Basis for Recommendation Visual Inspection
P Nagamanickam
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
P Nagamanickam
P Nagamanickam
Thank You
P Nagamanickam