Bharat Heavy Electricals Limited, Tiruchirapalli

Wl Welcome

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Bharat Heavy Electricals Limited, Tiruchirapalli

P Presentation t ti Arrangement A t
1. Introduction 1 I t d ti 2. Module of a typical RLA Study 3. BHEL contribution in the area of RLA 4. Unique Test Facilities at BHEL 5. Current developments in BHEL in the Field of RLA

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RLA in Life Extension Program

LEP

N on- pres su re P art s

Pres s ure P art s

Cond it ion As se ss men t

P ET

R LA

R&M Proposal p
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RESIDUAL LIFE ASSESSMENT STUDY

RLA study t d conducted d t d basically b i ll to t find fi d out t:

The present condition / problem areas of the Boiler

pressure parts and piping

To determine the remaining left f out life f of f the

pressure parts Enable to take Run, , Repair p and Replacement p decisions Provide technically sound and viable input for R&M
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Why RLA Study

Ageing of boilers consequent to creep / f i fatigue stresses in i pressure parts of f boiler b il

Material degradation due to corrosion, erosion and oxidation

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Why y RLA Study y

O Operation ti of f boiler b il at t elevated l t d temperatures more than design limit Variations in coal quality Deviations D i ti i Water in W t Chemistry Ch i t

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Why y RLA Study y

E Erosion i on on the th outer t surface f of f the th drum d due d to t steam leakage

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Why RLA Study

Sagged Header

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Why y RLA Study y

Foreign Body inside RH Inlet Header

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Wh RLA St Why Study d

Seawater Corrosion in S-Panel

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RLA Study Aims At

Evaluation of present condition of pressure parts t & piping i i 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

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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 N pressure parts Mostly maintenance oriented Can C be b assessed d easily il
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Module of a typical RLA Study

RLA STUDY
Pre-Site Study Phase
Tender Review/ Review of requirements based on available information

Site Study
Review of Operational History

Post-Site Study Phase

Laboratory Analysis Replica Evaluation Tube Sample Analysis

Discussions with Utility

Scheduling of Activities

Review & Finalisation of f Recommendations R d ti

Scope Finalisation

Preparatory Works

Report Preparation & Submission

Submission of Offer

Study & Preliminary Report Submission

proposals for improvement

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Steam Generating Unit

PRESSURE PARTS
HIGH TEMP (>400 C) HIGH THICKNESS
SH HEADERS, DeSH MS, , HRH & PRDS PIPINGS LTSH & RH O/L HEADERS

LOW TEMP (<400 C) HIGH THICKNESS

ECONOMISER HEADERS DRUM, , WW & SCW HEADERS CRH PIPING, LTSH I/L HEADER

HIGH TEMP (>400 C) LOW THICKNESS

SH, RH, LTSH UPPER BANK COILS

LOW TEMP (<400 C) LOW THICKNESS

WEAR PRONE COMPONENTS WW PANELS LTSH LOWER BANK, ECONOMISER COILS

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Various Components of Operation History

Operation History
S i H Service Hours G Generation ti Records R d M i t Maintenance Records R d

N of No. f St Start-ups t

A il bilit Availability

R l Replacement tR Records d

Transient Conditions

PLF

Design Changes

Steady State Conditions Excursions

Failure History

Inspection Records RLA/CA/PET

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Stages of Residual Life Assessment

Review

of

past

operational

&

maintenance data of the plant including water chemistry variations Field testing Laboratory testing
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Review Of Past Data

Plant operation
Number of start-ups & shut downs Operating p g conditions Operating practice

Maintenance M i t and d repair i

Failures and repairs Review of root cause analysis Details of modifications

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Field Testing

Vi Visual l inspection i ti Erosion, corrosion Swelling, scaling Deposits, Deposits misalignments Supports, pipe hangers etc Dimensional checks Thickness Outside diameter
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Field Testing g

Non destructive examination

Penetrant testing including fluorescent type Magnetic g p particle inspection p ( (Wet fluorescent & Dry) Ultrasonic In-situ hardness checks Eddy current testing

Tube sampling - WW internal deposits WW H2 embrittlement i

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Field Testing

SH/RH for oxide scales, scales Metallography In situ metallographic examination Fib Fibroscopic i inspection i ti Spot p chemical check when needed

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Typical yp Tests Done for RLA

High g temperature p headers & p piping p g

Ultrasonic, dye-penetrant tests Fibroscopy, Fib replicas li Other inspections like
Dimensions, Internal inspection p In-situ hardness

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Typical Tests Done for RLA Superheater S h t &R Reheater h t t tubes b

Tube samples, ultrasonic test OD & Thickness Deposit Analysis Steam side oxide scale thickness Life prediction

Attemperators
Ultrasonic, dye penetrant tests Replication, hardness Fibroscopy py
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Typical Tests Done for RLA

Drums D &d downcomers

Ultrasonic, , dye-penetrant y p tests MPI (Wet fluorescent & Dry) Fibroscopy

Furnace & convection pass tubes

Tube samples, ultrasonic test Deposit analysis (Internal & External)
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Steam Piping
Visual Inspection R li ti Replication, In-situ I it Hardness H d OD & thickness H Hangers & Supports S t I Inspection ti Stress analysis to identify the most stressed points G General l guidelines id li for f selecting l i inspection i i points i
High turbulence or velocity zones C d Condensation ti points i t Dead ends & high stressed points Areas immediately downstream of chemical injection points All supports pp

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Water wall Tubes Tubes samples from high heat flux zone
Detailed dimensional measurements Metallurgical analysis Presence of internal deposits covering
Deposit D it content t t Constituents of deposit Solvent S l t selection l ti if cleaning l i is i necessary

Presence of external and internal corrosion Micro structure analysis (hydrogen damage)

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Laboratory Testing

Microscopic examination (Light Microscopy & SEM) Deposit analysis ( Internal & External) Accelerated A l d creep rupture testing i Other mechanical & metallurgical tests

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Bharat Heavy Electricals Limited, Tiruchirapalli Scope of RLA as per IBR 391 A
Component Drum (Steam) Water Drum Low Temp header Attemperator Header High Temp Header Low temp eco tubes Convection SH coils Primary SH coils Prefinal SH coils Final SH Coils Reheater coils High temp header Final SH header Reheater Header M i steam Main t piping i i Platen SH header Primary SH header Economizer header Auxiliaries Boiler bank tubes Water wall Furnace water walls Ultrasonic Visual testing Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 'Yes Yes Y Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No Yes No No No No No No No Yes Yes Yes N *** No Yes Yes No No No No No Magnetic Liquid/Dye particel penetrant testing inspection No No No No No No No * * * * * * * Yes Yes Yes Yes No No No No No No No Yes Yes Yes N No Yes Yes Yes No No No No Deposit Replication Sampling A nalysis Yes Yes No Yes No No No No No No No Yes Yes Yes Y Yes Yes Yes No No No No No No No No No Yes Yes Yes Yes Yes Yes Yes No No No N No No No No No No Yes Yes Yes Yes No No No No Yes No No No No No No No N No No No No No No No No

No * No * No * No No No No N 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 g integrity g y of butt welds * * * UT for checking $ Header internal inspection by fiberscope

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Microstructural Evaluation By Replication

Sampling Thick Walled Components Is Not Possible Non-destructive Technique Adopted F Evaluation For E l ti Is I Replication R li ti . To examine spheroidisation p and cavitation level

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Replica p Technique q

The material surface preparation by grinding, polishing and etching Th The plasticised l ti i d replica li is i applied li d firmly fi l to the surface After curing, the replica can be removed and d gold ld sputtered tt d & the th topographical t hi l image of the micro structure is examined

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Bharat Heavy Electricals Limited, Tiruchirapalli

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Replication

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G ld Sputtered Gold S tt d R Replica li

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Creep p Cavity y Level Classification System y Proposed p by Wedel & Neubauer

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Codes & Standards to which work executed

Indian Boiler Regulations g ASME BS ANSI DIN

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Organisation for RLA in BHEL

Head / Engineering
R&M department
Scope of Work Technical , Report Preparation & Cl Clarification ifi ti

Supporting Depts Service After Sales

FES, WRI Central Lab NDTL R&D , C Corp R&D Offer Submission Order Receipt Report to Customer & B il Inspectorate Boiler I t t

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Supporting Depts For Specialised Work

NDE
TUBE FAILURE ANALYSIS WATER CHEMISTRY & INSITU METALLOGRAPHY OXIDE SCALE THICKNESS ACCELERATED CREEP RUPTURE TEST

NDTL,SAS & WRI

CENTRAL LAB

Corp. R&D

CENTRAL LAB, WRI

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Expert Panel For RLA

Engineering& R&D Metallurgical Analysis NDE

Doctorates : 5 Doctorates : 6 Post Graduates : 50 Post Graduates : 10 Graduates : 250 Graduates : 10

Level I : Level II : Level III :

43 136 6

Level L l I, I II & III as per ASNT SNT TC TC-IA IA Techniques UT, RT, MT, PT, Eddy Current (ET), & Leak Test (LT)
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BHEL WINS
National NDT Award from ISNT 4 times

Best UT Operator Award from ISNT Two Registered Assessors Qualified from I tit t of Institute fR Registered i t d&C Certified tifi d Assessors (IRCA, UK)

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BHEL special contribution contrib tion in the area of RLA

Level III NDE Experts Train The NDE Personnel, Boiler Inspectorate Personnel and Customers Personnel HRD Training Program on RLA Being Conducted for Education of BHEL Engineers, g , Customer Engineers & Boiler Inspectors g WRI & BHEL Indo-German Program Encompasses RLA also Carried Out Successfully 208 RLA Studies on Boilers Including Piping & Industrial Boilers & other Components p
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BHEL special contribution in the area of RLA (cont.)

Training of BHEL executives in the field of RLA at EPRI USA EPRI, Field Training at Chandrapura TPS by EPRI, USA A 500 MW Boiler RH header Modification with P 91 Material Based on Assessment by RLA Techniques Requirements on Availability Consequent to RLA Being Met When Called for Independent Evaluation by BHEL & Russian Team at SAIL, Bokaro in Full Agreement Technically

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Special NDT techniques developed by BHEL Detection of hydrogen damage by UT Measurement of oxide scale thickness by UT. UT Microstructural evaluation by replication A new technique called VAPINE'. Detection of ligament cracks in headers by UT.
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Unique Test Facilities at BHEL

Post Exposture p Uni-Axial Accelerated creep p testing g In-Situ Hardness Tester In situ Polishing Equipment for Replica Sampling In-situ Digital Strain Measurement Gauge Portable Microscope for Insitu Metallurgical Examination Portable Alloy Analyser 100 T Static dynamic MTS tensile testing machine with microprocessor
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Unique Test Facilities at BHEL (Cont)

Impact test facility up to minus 196 deg C Vacuum Emission Spectrometer Scanning Electron Micro Scope Atomic Absorption Spectrometer y Portable Stress Analyser Video Fibrescope

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Scanning g Electron Micro Scope p

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In situ Hydrogen Damage Detection In-situ

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Ligament g Crack Detection by y UT

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R Recommendations d ti F Format t (T (Typical) i l)

Residual life / inspection intervals of components Parts P t needing di replacements l t Parts needing g repairs p Chemical cleaning advice & procedure Modifications M difi i required i d for f life lif extension i
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Recommendations Format (Typical)

Advice on water regimes Improvements in operational methods Future plans of tests Retrofits / improvements in control & instrumentation Any other specific observations

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RLA studies di Carried C i d out b by BHEL

Total Number of studies carried out : 208 Power Boilers Process/Industrial Boilers : 138 : 70

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Run

Repair

Replace

RLA

Evaluates For All Phases

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Current working of BHEL in the RLA Field

Working on a comprehensive Advanced RLA soft

ware to evaluate pressure part creep and Fatique life assessment called ALIAS. The data to be fed to the software should be reliable and accurate. Planning to use in site with data availability shortly. shortly Strain measurement to Evaluate the safety factor of Drum as per ASME code Section 8UG L101. This compares the the current safety margin of the Drum with the ASME design safety margin for the drums with considerable service >15 years. years
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Thank You
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