This document provides an overview of erosion protection measures and operational influences on boiler tube metal temperatures. It discusses common causes of tube failure such as burst, erosion, corrosion, and fatigue. Specific failure modes like long-term overheating, short-term overheating, soot blower steam erosion, and falling slag erosion are examined in detail. Corrective actions and design improvements to reduce tube failures are proposed. Locations prone to different erosion types are identified along with probable root causes and remedies.
This document provides an overview of erosion protection measures and operational influences on boiler tube metal temperatures. It discusses common causes of tube failure such as burst, erosion, corrosion, and fatigue. Specific failure modes like long-term overheating, short-term overheating, soot blower steam erosion, and falling slag erosion are examined in detail. Corrective actions and design improvements to reduce tube failures are proposed. Locations prone to different erosion types are identified along with probable root causes and remedies.
This document provides an overview of erosion protection measures and operational influences on boiler tube metal temperatures. It discusses common causes of tube failure such as burst, erosion, corrosion, and fatigue. Specific failure modes like long-term overheating, short-term overheating, soot blower steam erosion, and falling slag erosion are examined in detail. Corrective actions and design improvements to reduce tube failures are proposed. Locations prone to different erosion types are identified along with probable root causes and remedies.
This document provides an overview of erosion protection measures and operational influences on boiler tube metal temperatures. It discusses common causes of tube failure such as burst, erosion, corrosion, and fatigue. Specific failure modes like long-term overheating, short-term overheating, soot blower steam erosion, and falling slag erosion are examined in detail. Corrective actions and design improvements to reduce tube failures are proposed. Locations prone to different erosion types are identified along with probable root causes and remedies.
BY T.MOHAN Presentation on “Erosionprotection Measures operational influence on Tube metal Temperature” Prepared by: T.MOHAN Sr.Manager Pr parts arrangement of 110 MW boiler Service failure of boiler tubes
2. Excessive internal deposit 3. Flame impingement 4. Exposure to direct radiation 5. Flue gas circulation pattern 6. More Excess air Long Term Overheating
7. Improper material 8. Exposure to high flue gas temperature due to blockage of gas or laning. 9. Periodic over firing /uneven firing of fuel burners. Short Term Overheating
1. In adequate fluid flow
2. Blockage 3. Maintaining drum level 4. Foreign material entry while maintenance Lack of Strength
1. Wall thinning by erosion.
2. Wall thinning by corrosion. 3. Material deterioration. 4. Improper heat treatment. 5. Improper fabrication/Erection weld joints. Erosion
• Fly ash erosion
• Falling slag erosion • Soot blower steam erosion • Coal particle erosion • Secondary erosion due to steam impingement. • Rubbing of tubes Tube failure analysis from a major state electricity board in India • Long term over heating - 24 • Short term over heating - 09 • Soot Blower Steam erosion - 17 • Flue gas erosion -35 • Fuel air erosion - 05 • Falling slag erosion - 01 •DMW failure -07, • Water side corrosion -15, • Fatigue - 04, • Hydrogen embrittlement - 03, • Material mix up -03, • Weld defect -02, • Others -05. Total 130 Nos Fly Ash Erosion Typical Locations Corrective Action • RH coils • LTSH coils • Use low ash ( coal /-quartz) coal. • Economiser coils and hangers • Changing operating conditions like • Areas close to large ash accumulation reduced load, low excess air etc. - WW screen • Protections like shields, baffles, Probable Root Cause refractory, coating etc. • Non-uniform, excessive gas flow with • Flow Model study fly ash particles • Increase in gas velocity. • High ash coal with -quartz. • Tube misalignment. • Excessive gap Factors Influencing Ash Erosion In Coal Fired Boilers
1. The velocity of flue gas
2. The mineral content in coal
3. The change in direction of flue gas
4. The arrangement of pressure parts
5. The temperature of flue gas
6. Bypassing of flue gas
Flue gas velocity
1. Earlier BHEL adopted 12 – 13 m/Sec in second
pass. 2. Presently 10 -11 m/sec further reduction to 9-10 m/sec 3. Very low velocity in second pass leads to ash settling etc. 4. Rate of erosion increases by power 3 to 5. 5. Power depends on alpha quartz and structure of quartz. Fly ash Erosion
• Erosion is more in boiler back pass where the gap between the coils/assemblies is less and gas temperature is also less.
• Erosion rate depends on
» gas velocity » alpha quartz and pyrite content » ash content (erosive particles like silica, alumina, iron oxide etc) » Fly ash mass » angle of impact ( < 45° has more effect) Fly Ash Erosion EROSION IN SECOND PASS <B> Falling slag erosion Typical Location:
1. Furnace bottom slope (S panel of front and rear
WW) mainly the area close to side WW.
2. Side WW close to bottom slope.
Probable Cause:
1. Fuel characteristic for fouling.
2. Improper combustion. Falling slag erosion Corrective action 1. Check the fuel characteristics for fouling. 2. Change fuel if warranted. 3. Tuning the boiler air regime for optimised combustion to avoid fouling. 4. Welding of wear bars at the bottom S-panel tubes to break the ash boulders and to avoid direct hitting of the tubes. 5. Increase tube wall thickness. Soot blower steam erosion Typical Location: 1. Around wall blower opening (about 1m radius)- Steam impingement area. 2. First tubes near wall entrance of retractable blowers. 3. Direct path of soot blowers
Probable cause: 1. Condensate formation during idling and water impingement on WW during subsequent blowing. 2. Blower getting stuck-up. 3. Degree of superheat of blowing steam (about 15 to 20 C above the saturation limit) not being maintained. 4. Non availability of thermal drain system. 5. Improper alignment /damaged nozzle. Corrective action 1. Ensure wall blower nozzle alignment 2. Check the blowing pressure 3. Ensure condensate free steam with a minimum superheat of (about 15C above the saturation temp) at blower. 4. Necessary gradient/downward slope of the SB piping is to be ensured. 1 per meter length of pipe is to be maintained. 5. Thorough thickness survey of WW in the SB location for 2 meter radius and replacing the eroded tubes. 6. Temporary shielding / spraying. 7. Installing thermal drain system if not available. 8. Smart wall blowing system. Coal particle erosion
Typical location:
• Burner nozzle Design Improvements to reduce Tube Failure …
• Optimum flue gas velocity over tube banks
• Plain tube in-line arrangement of heat transfer surface • Optimum end gaps to avoid preferential gas flow • Erosion protection shields / cassette baffles • Erosion allowance for leading tubes Eco inlet coil metal build up in LTSH terminal tubes FOREIGN MATERIALS IN SCW INLET HEADER WW hanger tubes are touching the RH coils and dent mark observed in WW hanger tubes at the touching portion. Any Questions Please Thank You
