ABSTRACT

In todays modern power plant, where high pressure boilers are used,
boiler tube failure continues to be the loading cause for forced outages in
fossil fired boilers. The problem due to tube failure is only realized when the
cost due to failure cost is estimated. The main objective of the proposed
project is to reduce occurrence of the tube failure occurring at, mettur
thermal power station and provide suitable remedies for it. The major
problem incurred while analyzing are found to be flue gas erosion, long term
overheating and steam erosion. Flue gas erosion problem causes the most
severe damage amongst all, as it affected the external part of boiler tube
directly. Investigation is being carried out based on experimental study to
find out the present state of the water tube boilers causing flue gas erosion.
Further by CFD analysis, it is proposed to determine the optimum scale
thickness which effects the heat transfer rate.

TABLE OF CONTENTS
CHAPTER
NO.

TITLE

PAGE
NO.

Abstract

List of Figures

II

List of Tables

III

Nomenclature

IV

Introduction

1.1 Mettur Thermal Power Station

1.2 Mtps Units Commissioning Dates

1.2.1 Installed Capacity 840mw (4x210mw)

1.3 Overview Of Thermal Power Plant

7
7

1.3.1 Steam Generation Boiler

1.3.2 Boiler Tube Arrangement

1.3.3 Boiler Type

1.3.4 Overview Of The Thermal Power Plant

10

1.3.5 Mettur Thermal Power Station Salient

Features

10

1.4 Steam Cycle For 210 Mw Units

13

1.4.1 Water Walls

14

1.4.2 Super-Heaters

14

II

1.4.3 Reheater

15

1.4.4 Types Of Sh & Rh

15

1.4.4.1 Arrangements Of SH And RH

16

1.4.5 Economiser

16

1.4.5.1 Economiser Tube Arrangement

17

1.4.5.2 Location & Arrangements

17

1.5 Typesof Failure

18

1.5.1 Areas Of Failure

18

1.5.2 Failure Occuring At Mtps

18

1.5.3 EROSION

19

1.5.4 Stress Rupture

19

1.5.5 Welding Defect

20

1.6 Causes Of Tube Failure

20

1.6.1 Erosion

21

1.6.2 Fly Ash

21

1.6.3 Coal Particles

22

1.6.4 Slag Formation

22

1.6.5 Air Erosion

22

1.7 Street Rupture

22

1.7.1 Short Term Overheating

23

1.7.2 Long Term Over Heating

23

1.8 Causes Of Super Heater Tube Failure

24

III

1.8.1 Fire Side Corrosion

24

1.8.2 Furnace Wall Corrosion

25

1.8.3 Coal Ash Corrosion

26

1.8.4 Oil Ash Corrosion

27

1.8.5 low temperature corrosion

28

1.9 Erosion

29

1.9.1 ABRASIVE EROSION

29

1.9.2 Liquid Impingement Erosion

30

1.9.3 Cavitation Erosion

31

1.10 Fatigue

31

1.10.1 Mechanical Or Vibratory Fatigue

32

1.10.2 Thermal Fatigue

33

1.10.3 Corrosion Fatigue

34
36

literature review
2.1 Failure Analysis Of Scale Formation

36

2.2 Cfd Modeling Of Boiler Tube Failure

38

2.3 Failure Analysis Of Boiler Tubes Due To

Fireside Corrosion

42

2.4 Creep Failure Of Boiler Tube

47

2.5 Long Term Overheating Of Tube Failure

48

2.6 Short Term Overheating Of Tube Failure

49

2.7 Fire Side Erosion of Failure

49

2.8 Oxide Scale Formation Of Failure

50

IV

2.9 Heat Transfer Tube Failure Analysis

50

2.10 Heat Flux Of Tube Failure

51

Mathematical Calculation

53

3.1 Final Super Heater Parameters And Readings

53

3.2 Tube material with oxide limits

54
54

3.3 Flue Gas Temperatures At Different Location

In The Boiler
3.4 Feed Water And Steam Temperature At

55

Different Location In The Boiler

3.5 Super Heater Section

56

3.6 Estimation Of Temperature Distribution

57

3.7 Direct Method

57

3.8 Indirect Method

58

3.9 Design Procedure of economizer tube heat transfer

55

Conclusion and future scope

57

References

58

LIST OF TABLES

TABLE

NAME OF THE TABLE

NO.

PAGE
NO.

1.1

Installed Capacity Of Plant

1.2

Failure Due To Erosion

19

1.3

Stress Rupture

19

1.4

Welding Defect

20

3.1

Final Super Heater Parameters

53

3.2

Flue gas temperature at different location in the

boiler

54

3.3

Feed water temperature and steam at different

location in the boiler

54

3.4

Super heater section

55

4.1

Remedy for tube failure

56

VI

VII