210 MW POWER PLANT SG

Boiler drum
Reheater
Final Super
Platen Super heater
heater LTSH

Economizer
Coal bunker
Wind Box
Secondary
air duct PA duct
Furnace
Flue gas
APH duct Coal feeder

F D Fan P A Fan
Coal
Pulverizer
Iron Carbon Equilibrium Diagram
 ASME Grade  Carbon Mg Si Cr Mo P S

SA 210 Grade A1 0.27 0.93 0.1 min     0.048 0.05

SA 210 Grade C 0.35 0.29-1.06 0.1min     0.048  

SA 209 T1 0.1 -0.2 0.3-0.8 0.1-0.5   0.44-0.65 0.045 0.045

0.44 -
SA 213 T11 0.12 max 0.3-0.6 0.5-1.0 1.0-1.5 0.03 0.03
0.65
0.87 -
SA 213 T22 0.12 max 0.3-0.6 0.5 max 1.9-2.6 0.03 0.03
1.13

SA 213 T 91       9 1    
BOILER TUBE FAILURE
MECHANISM: Long Term Overheating
Failed FSH tube :BTPS’B’
DTPS U#3 – Final SH outer loop failure due to Creep
BOILER TUBE FAILURE
MECHANISM: Short Term Overheating (Blockage
of tube during Mtc.)
 BTPS-B U#3

Final S/H,C-25,T-6 – Short Term

Overheating (Chocking)
DATE-09/08/06

UNIT 5
(1 MONTH AFTER OVERHAULING)

AREA-PLATEN SUPERHEATER COIL 6

REASON-SHORT TERM OVERHEATING

ACTION TAKEN/PLAN-
• COMPLETE INSPECTION,
• OXIDE SCALE
• FIBROSCOPY
• RADIOGRAPHY
RH Coil Erosion : BTPS’B’
 RH Coil Bends : BTPS’B’

Misaligned coils further aggravated erosion rate

 Internal Damage due to Oxygen pit

Reasons:
• Presence of oxygen
• Presence of moisture
• Inadequately protected metal surface
• fractures of protective magnetite layer.
Oxygen pits can act as stress-concentration sites, thereby fostering the
development of corrosion-fatigue cracks, caustic cracks, and other stress-
related failures.
 BOILER TUBE FAILURE
MECHANISM: Thermal Fatigue
 Station CTPS U#3 : WaterWall tube
Improvement of Water Chemistry &
Stringent monitoring of Chemical Tubes failed due to Hydrogen
Parameters Embrittlement
BTPS’B’ U#1 Water wall micro structural Analysis: R&D
centre

Caustic Gouging
 CTPS Platen Water Tube failure

Tubes failed due to Hydrogen

Embrittlement
W/Wall Tube failure : DTPS U#3 - Erosion due to burner
33
Damaged Burner – DTPS U#3
 BTPS’B’
Baffle Wall Erosion (Severe Dent) near Primary
SH bottom bank

Eroded Primary SH bottom

Bank tubes

Increasing trend of failure of Primary SH Bottom Bank outer

Loops & Baffle Wall in U # 3 & 2
Post CAVT wire mesh installed in 2nd pass BTPS’B’U-2
Post CAVT wire mesh installed in 2nd pass BTPS’B’U-2
 BOILER TUBE FAILURE
MECHANISM: CHEMISTRY RELATED
Area of Leakage
 DIAGNOSIS OF BTF

• ACTION PLAN BASED ON FAILURE ANALYSIS

 SHORT TERM
 LONG TERM

• HISTORY OF TUBE FAILURES

 PHOTOGRAPHS
 DATA FORM

• MAPPING OF TUBE FAILURES

• BATH TUB CURVE
 BTL Action Plan

• Internal scale analysis of Water wall for qualitative & quantitative

analysis & necessary corrective measure.
• Timely replacement of Burners.
• Replacement of CI burners with modified SS Tip. Tuffa Coating to
Burner arch panel.
 Close monitoring of Dissolved oxygen & addressing Air ingress to
condenser completely.
 In-situ oxide scale measurement of high temp. SH tubes for remedial
measures. Replacement criteria is based on scale growth > 350
micron & thickness reduction of more than 25 %.
 Comprehensive replacement of Platen & Final SH outer loops which
have outlived their useful service life.
• Complete Restoration of all Chair supports, Clits, spacers for RH &
Primary SH.
• Restoration of binder support of Economiser coils.
 BTL Action Plan
• Ensuring verticality & equal spacing of each coil.
• Ensuring equal transverse gap between pair of coils at 3 locations
i.e. one at each ends and middle of the coil.
• Ensuring equal Longitudinal gaps between coil and front/rear wall
• Installation of Chicken wire mesh / Scallop over Primary SH, RH
Banks to minimize erosion of bends.
• Alignment of Economiser side wall tubes
• CAVT & installation of wire mesh for uniform Gas Distribution.
• Modular Replacement of erosion prone coils in 2nd pass.
• Radiography of old joints in the vulnerable areas as per failure
history & 100 % Radiography for new joints.
• Stop usage of Gas Cutting
• H.P Welder test- before Unit OH.