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Damage to Utility Boilers by Cycling and Flexible Operation: Report on the State of Knowledge
Product ID:1023830 Date Published:28-Nov-2012 File size:6.39 MB Sector Name:Generation Document Type:Technical Update FileType:Adobe PDF (.pdf) This product is available at no cost to funding members only. If you are a member, you must Log in to access. Price:$ 25,000 (US Dollars) If you are a non-funding individual or entity and wish to purchase this document, please contact the EPRI Order Center at 1-800-313-3774 Option 2 or 650-855-2121. You may also send an e mail to orders@epri.com. Abstract

The focus of this report was twofold. First, the initial concept and implementation of a boiler component and damage mechanism ranking were developed, based on the effects of cycling. This state-of-knowledge ranking can be used for determining the emphasis of future research on components most affected by cycling. Second, the groundwork for these boiler components and damage mechanisms was laid for the development in the second phase of this project of the report, The Impact of Flexible Operation and Unit Cycling on Boiler Component Damage: Theory and Practice.

Background
The consequence of severe unit cycling is often not known or not well understood by utility operators because of the number of complex effects. For example, pressure part failures or detectable damage that is accelerated by a given operating event is generally delayed by at least several months and sometimes by several years. Initially, it might appear to plant operators that their unit is robust and able to tolerate recurring, severe operating events. In reality, the effects of these operating events result in substantial damage to the unit, but the damage seldom results in immediate component failure and might not even present any detectable damage.

Challenges and Objectives


The development of the boiler component and damage mechanism ranking showed that additional research must be performed before the working ranking is more fully developed. The nature of cycling requires the consideration of many factors to develop the theory and practice report.

Approach

This work will provide the industry with an understanding of the most troublesome and costly boiler damage mechanisms that are influenced by unit cycling.

Results and Findings


The following conclusions were found from the surveys that determined component damage mechanism rankings:

Many of the damage mechanisms are dependent on specific conditions at individual units, which is indicative of the nature of the effect of cycling on damage mechanisms. The state of knowledge for many of the damage mechanisms is incomplete or not widely known or up to date. The ranking values should be considered incomplete, and they should be considered flexible until additional research is performed. The survey did not determine which component and damage mechanisms are most troublesome. Instead, it focused on the extent that unit cycling might influence each damage mechanism.

Applications, Value, and Use


The final goal of this project, the development of the report The Impact of Flexible Operation and Unit Cycling on Boiler Component Damage: Theory and Practice will allow users to identify issues developed as a result of cycling, develop an understanding of the state of knowledge of the damage mechanism, identify or monitor the damage mechanism, estimate the damage caused by the mechanism, and determine possible corrective actions to mitigate the damage mechanism.

Program 2012 Program 63 Boiler Life and Availability Improvement Program Keywords

Boilers Cycling Damage Mechanism Flexible operation Report 000000000001023830 Note

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