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analysis with
Modified Design
FAILURE DETAIL
1.1) Failure Types:
There are six reason for failure in Boiler Tube:1) Water-side corrosion
2) Fire-side corrosion
3) Erosion
4) Fatigue
5) Heating
6) Lack of quality control
1.2) Detail Types Of Failures :1.2.1) Water-Side Corrosion: There are five types of effect due to water impurities.
1) Caustic corrosion
2) Oxide corrosion
3) Hydrogen Damage
4) Pitting (Localized Corrosion)
5) Stress Corrosion Cracking
1.2.5) Heating:-
CHAPTER-1
1.3) Feed Water Treatment & Chemical Cleaning:1.3.1) Objectives:1.3.1.1 Pretreatment Of Water
1.3.1.2 Demineralization
1.3.1.3 Chemical Conditioning of Water
Chapter-2
Problem: Loss on the inside diameter (ID) surface of the tube, stress and
strain in the tube wall is increases.
Problem: Aggressive localized corrosion and loss of tube wall is near economizer
feed water inlet on operating boilers.
Causes: Oxygen corrosion occurs with the presence of excessive oxygen in boiler
water. It can occur during operation as a result of in-leakage of air at pumps, or failure
in operation of pre-boiler water treatment equipment.
This also may occur during out-of-service periods, such as outages and storage, if
proper procedures are not followed in lay-up. Non-drainable locations of boiler
circuits, such as super heater loops, re-heater tubes and supply lines, are especially
susceptible.
Wetted surfaces are subject to oxidation as the water reacts with the iron to form iron
oxide.
2.1.3) Hydrogen Damage: Problem: Due to Internal micro-cracking. Loss of ductility of the tube
material leading to brittle rupture in boiler tube.
Water chemistry is upset, such as what can occur from condenser leaks,
particularly with salt water cooling medium, and leads to acidic (low pH)
contaminants that can be concentrated in the deposit.
The source of corrosive fluid may be carryover into the super heater from the
steam drum or from contamination during boiler acid cleaning if the super
heater is not properly protected.
For conventional fossil fuel boilers, corrosion in the burner zone usually is
associated with coal firing.
Boilers operating with staged air zones to control combustion can be more
susceptible to larger local regions possessing a reducing atmosphere,
resulting in increased corrosion rates.
Causes: It usually is associated with coal firing, but also can occur for certain types of
oil firing.
Ash characteristics are considered in the boiler design when establishing the size,
geometry and materials used in the boiler. Combustion gas and metal temperatures in
the convection passes are important considerations.
Damage occurs when certain coal ash constituents remain in a molten state on the
super heater tube surfaces. This molten ash can be highly corrosive.
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Problem: Damage will be occurs on inner side of the tube. Ultimate failure results
from rupture due to increasing strain as tube material erodes away.
Causes: Erosion of tube surfaces occurs from impingement on the external surfaces.
The erosion medium can be any abrasive in the combustion gas flow stream, but most
commonly is associated with impingement of fly ash or soot blowing steam.
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Problem: Damage most often results in an outer diameter (OD) initiated crack. Tends
to be localized to the area of high stress or constraint.
Causes: Fatigue is the result of cyclical stresses in the component. Distinct from
thermal fatigue effects.
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low-amplitude stresses), or they may be associated with boiler cycling (lowfrequency, high-amplitude, stress mechanism).
Fatigue failure most often occurs at areas of constraint, such as tube penetrations,
welds, attachments or supports.
Problem: Failure results in a ductile rupture of the tube metal and is normally
characterized by the classic fish mouth opening in the tube where the fracture
surface is a thin edge.
Causes: Short-term overheat failures are most common during boiler start up.
Failures result when the tube metal temperature is extremely elevated from a lack
of cooling steam or water flow.
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Problem: Tube metal often has heavy external scale build-up and secondary
cracking. Results in tube failure.
Furnace water wall tubes also can fail from long-term overheat. In the case of
water wall tubes, the tube temperature increases abnormally, most commonly from
waterside problems such as deposits, scale or restricted flow.
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2.6) Lack Of Quality Control:2.6.1) Maintenance Damage & Metallurgy Defects: Problem: Maintenance damage & Material defect are occurs due to methods &
materials used in analysis of boiler tube.
Cause: If proper methods & material not used in it , then it cause in boiler. High
quality methods & material to be used in boiler tube failure are more expensive.
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CHAPTER 3
3.1) Objectives of Treatment:Treatment and further conditioning of water are necessary for the following
objectives:
To prevent scaling internals of pressure vessels due to dissolved and suspended
impurities,
To prevent corrosion of metallic parts of the boiler, with which water / steam
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Following are the impurities in the natural water which are to be cleaned.
1) Dissolved impurities:
Mainly the dissolved solids found in water are mineral salts. These
contaminants in water exist as salts of calcium, magnesium and sodium.
To a lesser extent, potassium and iron salts are also present. Nitrates and
silicates of such substances are also found to a small degree. Very rarely,
Phosphates and a few heavy metals are also found in natural water.
The quantity and composition of the solids present depend upon the soil and
strata details and the origin of water.
Various gases, mainly Oxygen, and others like Carbon dioxide and Hydrogen
Sulfide are normally present in dissolved form and the presence of such
dissolved gases alter the composition and concentration of certain salts.
2) Dissolved Oxygen:
Dissolved oxygen plays significant role in boiler feed water. The oxygen
accelerates corrosion of water tube material. Mainly oxygen is removed only
3) Total Solids:-
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The basic idea is to restrict impurities in feed water as low as possible in order
to avoid rise in boiler water concentration and deposition of metal oxides in
the boiler.
4) Organic Matter:
Quality of raw water at intake point is a deciding factor. Seasonal changes play
a vital role.
5) Chlorides:
Clay and sand particles constitute a major portion of the suspended matter.
Very fine clay remains in colloidal state. Colloidal suspension of dye material
and certain organic contents, give color to water, in most cases.
Normally the mineral salts dissolved in water are found to exist in the ionized
form. Generally there is no uniformity in quantity and proportion of such
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dissolved salts, since their presence is mainly dependent on the sources of the
water.
Ca ++ (Calcium)
HCO3- (Bicarbonate)
Mg++ (Magnesium)
CO3-- (Carbonate)
Na+
SO4-- (Sulphate)
(Sodium)
Fe++ (Iron)
Cl-
(Chloride)
Al+++ (Aluminium)
NO3-
(Nitrate)
PO4--- (Phosphate)
SiO2
(Silica)
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3.1.1.1) Clarification:
Pre- treatment to raw water is mainly to make it suitable for further processing of
water by Deionization units.
The water entering De-mineralizer plant should be free from suspended, colloidal
and organic impurities and the process of pretreatment plays a vital role in
ensuring proper feed input is made to Deionization units.
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A precipitator inlet flow control valve controls the raw water inlet flow into the
clarified water basin, through a level controller.
A manual by-pass valve is also provided to the level control valve, so that in case of
problem in the level control valve, manual operation can be done to maintain the
level.
The raw water enters the inner mixing zone through an open channel from the top and
flows downward into the inner conical tank.
The chemicals are let into the open channel to get mixed thoroughly with the raw
water flowing along the open channel into the mixing chamber. A water flow
indicating mechanism is fitted in the open channel to indicate the raw water flow.
Ferrous sulphate solution is delivered into the Precipitator by means of twin head
proportional feed 5% solution dosing pump.
The following chemical equations illustrates the chemical reaction of lime with the
calcium and magnesium bicarbonates:
Ca ( OH ) 2
CO2
CaCO3
H2O
Ca ( OH )2
Ca ( HCO3 )2
2CaCO3
2H2O
2Ca ( OH )2
Mg ( HCO3 )2
MgCO3 + CaCO3 +
Ca ( OH )2
MgCO3
Mg( OH )2
2H2O
2CaCO3
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(Insoluble)
The precipitated chemical in this reaction with the Calcium and Magnesium salts,
form an effective sludge in layers, which can be easily removed by blowing down.
Whatever the residual calcium, magnesium and sodium salts and silica still
present in the clarified water are removed by the successive ion exchange process
with the resin beds in the water de-mineralizing plant.
3.1.1.3) Filtration:
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Pressure units: which, as their name implies, are operated on line, under
service pressure, filtering the water as it flows the tank on its way to service or
storage
Backwashing:
When differential head between inlet and outlet increases, the filters must be taken
out of service and backwashed for removing accumulated dirt and sludge
materials.
For back wash the flow direction is reversed that is the inlet is given at the bottom
and water from the top is delivered out to open canal.
When the water flows in reverse direction it carries all the accumulated dirt and
sediments and throws out along with the water. The back washing is to be done
until the out flowing water is perfectly clear of all accumulated sediments.
Chlorine removal:
To avoid algae formation chlorine is dosed into raw water, before the process of
clarification in the clariflocator.
Hence before admission to cation vessel, the water is once again filtered treated in
a vessel containing a bed of Activated Carbon. Activated Carbon Bed absorbs left
over chlorine and the organic matters and feeds clear water to the ion exchange
vessels.
3.1.2) De-mineralization:
Demineralization is the removal of dissolved ionic impurities that are present in water.
Demineralized water is commonly produced by one or a combination of the following
processes:
1. Ion exchange
2. Membrane desalination
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3. Thermal desalination
The method selected to produce demineralized water depends on the quality of the
influent water, the required quality of the effluent water, the availability of resources
such as regenerant chemicals and waste water treatment and disposal requirements.
The economics of the processes that produce acceptable effluent quality must be
evaluated to determine the most cost-effective method for a specific application.
Basically the minerals present in water are in ionized condition. Ion exchange
demineralization therefore is one of the most important and widely applied
processes for the production of high-purity water for power plant services, and
it is accomplished using resins that exchange one ion for another.
Cation resins are solid spherical beads with fixed negatively charged sites and
exchangeable positively charged sites. Anion resins are solid spherical beads
that have fixed negatively charged sites and exchangeable negatively charged
sites.
Cation resin:
R-H+ + C+ R-C+ + H+
2R-H+ + C2+ R2-C2 + 2H+
Anion resin:
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The hydrogen ions (H+) displaced from the cation resin react with the
hydroxide ions (OH-) displaced form the anion resin. The net effect is the
dissolved ions are removed from the water and replaced by pure water (H2O).
The ion exchange resins are contained in ion exchange pressure vessels. The
ion exchange resin in the vessels is referred to as the resin bed. This process of
exchanging dissolved impurities is cyclic.
When a resin bed site is exchanged with a dissolved ion, the site becomes
exhausted and cannot remove other impurities without releasing an impurity.
Exhausted resins must be regenerated to return the resin beads to the original
hydrogen form for cations and hydroxide form for anions before further ion
exchange can take place.
Cation resins are commonly regenerated with a strong acid solution of either
sulfuric or hydrochloric acid.
Sulfuric acid does not present the fuming problems associated with
concentrated hydrochloric acid and is easier to handle (material selection).
Consequently, sulfuric acid is frequently the recommended regenerant for
cation resins.
Anion resins are commonly regenerated with a sodium hydroxide solution. As
can be seen from the regeneration reactions listed below, regeneration is the
reverse reaction to the impurity exchange reactions.
Demineralization of water renders raw water fit for use as make up and feed to a
boiler. Just feeding a boiler with Demineralize water, which is free of all
impurities, alone, will not suffice in reality due to the following reasons.
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a) When the steam is continuously being generated and released for process,
the water inside the drum gets more and more concentrated, even with the
very little and negligible level of impurity in feed water.
b) Further the pH of Demineralized water normally remains to be close to
neutral and will induce low pH corrosion of tube and pipe materials.
c) Demineralized water when under storage absorbs atmospheric air and the
level of dissolved Oxygen in water increases. Presence of Oxygen in feed
water again renders it corrosive.
Chemical treatment is done at various stages for feed and boiled water, steam and
return condensate, in order to ensure adequate protection is established over the
entire system, to help prevention of direct attack on parent metal by the corrosive
elements present in water / steam cycle.
The chemical treatment technique is based on several factors. While the overall
conditioning concept remains the same, there would be variations in the methods
adopted and the residual levels optimized, it depends mainly on:
a) Deferent grades of ferrous and alloy metals which are deployed in the
design and manufacturing of various pressure part components, such as,
water wall tubes, headers, raiser tubes, economizers, super heaters,
reheaters etc. and so many other equipment down the line such as turbines,
condensers, various stages of regenerative system heaters and the pumps,
d) Release of heat flux density, depending on the fuel fired and the design and
size of the furnace,
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e) Capacity of boiler for steam generation and the level of steam purity
expected,
The feed water is then chemically conditioned further with dosing of chemicals to
ensure that the dissolved oxygen content of the water is reduced to the minimum.
Hydrazine hydrate is normally employed for this purpose.
It is a direct contact type heater and is located between LP heater and Boiler feed
pump in feed water cycle.
The steam from suitable turbine stage is drawn to heat the condensate which is broken
in fine particles for effective heating and mass transfer on non-condensable gases.
The condensate to be de aerated enters the chamber at a top and is sprayed by variable
orifice spray valves. The water then falls through perforated tray stack or spill over
tray track by gravity.
The condensate is divided in to fine droplets and comes in the contact with the steam
resulting in release of non-condensable gases carried by steam moving up wards.
The condensate leaving the de aerator enters and collected to feed storage tank and
goes to Boiler feed pump
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The De-aerator removes the non-condensable gases by heating the condensate which
reduces the solubility of non-condensable gases and then allow mass transfer time to
reduce non condensable further.
The steam flowing upward provides the atmosphere for mass transfer and condensate
droplets while carrying away non condensable gases. The trays divide the condensate
in to fine droplets so that heating and mass transfer is achieved quickly.
The steam admittance in storage tank provides steam blanket over stored condensate
and thus eliminate sub cooling and re absorption of gases.
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It is fabricated from steel plate of boiler quality closed with dished end. The shell
is mounted over the feed storage tank. It contains steel trays. The distribution
chamber is located at the top in which spray valves are provided for spraying
condensate.
Spray valves are spring loaded disc. The variable opening is controlled by flow.
Perforated trays have no of small size holes through condensate falls down. The
annual and central opening is for flow velocity of steam, non-condensable and
pressure equalization.
In case of spill over tray a series of channel type trays are arranged such that,
condensate spills over from one layer to other layer.
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Quality requirement for feed water is very much dependent on drum operating
pressure. Hence recommended feed water quality is always expressed for a
particular range of boiler operating pressure.
Table No. 3.3.1 :- Quality of feed water
60
80
100
120
130
&
above
pH at 25 C
8.5~9.
8.5
9.0
~ 8.7 ~ 9.0
8.8 ~ 9.2
8.8~ 9.2
< 0.5
< 0.4
< 0.3
< 0.2
micro mhos/cm
Economizer inlet
< 0.01
< 0.01
< 0.005
< 0.005
< 0.005
< 0.03
< 0.01
< 0.01
< 0.01
< 0.01
<
< 0.005
< 0.003
< 0.003
< 0.003
0.005
Total iron copper & nickel ppm
< 0.03
< 0.02
< 0.02
< 0.02
< 0.01
< 0.02
< 0.02
< 0.02
< 0.02
< 0.01
Nil
Nil
Nil
Nil
Nil
Oil ppm
Hydrazine N2H4 ppm )
Nil
< 0.1
Nil
Nil
Nil
< 0.05
< 0.05
Nil
MODIFIED DESIGN
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Chapter-4
4.2)
4.2.1)
Fig 4.2.1(A), (B) and (C) shows the present & modified design of feed control
valve arrangement.
In fig. 4.2.1 (a) drum level controlled by the feed control valve by 60-70 percent
open and the differential pressure across the feed control valve is 15 kg per square
senti-meter by boiler feed pump scoop.
Fig.4.2.1 (b) shows the signal flow arrangement of feed water flow, drum level
and steam flow.
Fig.4.2.1 (c) shows the new modified arrangement of the whole control system.
So, the new drum level controlled by boiler feed pump scoop and feed control
valve 1 and 2 keeps fully open.
Now in modified design the differential pressure across the control valve is 0 to
0.5 kg per square senti-meter.
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Fig. 4.2.1(c) Modified Boiler Feed Pump & Feed Control Valve
4.2.2)
Fig. 4.2.2 (a) and (b) shows the piping arrangement of water flow form boiler
feed pump to the super heater with control valve arrangement.
In fig.4.2.2 (a), when the inlet pressure is 165 kg per senti-meter square then at
outlet the orifice meter gives the pressure reading is 160 kg per senti-meter
square. That means there is loss of pressure between inlet and outlet by the
control valve.
In fig. 4.2.2 (b) show the rearrangement of orifice meter to solve this pressure
drop across the boiler feed pump and super heater.
4.2.3)
Re-Heater design:-
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Fig.4.2.3 shows the water flow from boiler feed pump to the re-heater.
Present pressure in boiler feed pump is 150 kg per senti-meter square. Due to this high
pressure the damage occurs in the spray nozzle.
To prevent this damage put the pressure control valve ahead of spray control valve
and also make one reservoir tank between the controller and spray control valve.
4.2.4)
Piping Design:-
Fig. 4.2.4 (a) and (b) shows the piping arrangement of boiler feed pump line.
As shown in fig.4.2.4 (a) the pressure difference between boiler feed pump & header
pressure is 10 kg per senti-meter square. This pressure difference is occurs due to T
joint of the pipe line.
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In cooling water sump house, make the simple spray type arrangement. By this the
natural air passes through the spray and natural cooling is occurs.
Due to this the temperature of the water can be reduced. So, cooling process can be
made easily in cooling water sump house.
4.2.6)
Due to continuous use of air operated instrument (vacuum pressure operated), amount
of water and silica particles are increases which cause to stop the working of
instruments.
So, to solve this problem make one reservoir tank near the main valve. Due to this
silica and water particles fed in bottom of the tank and fresh air can be made and life
of the instrument can be increases.
Fig. 6 (a) and (b) shows arrangement of reservoir tank with control valve.
4.2.7)
ADVANTAGES OF MODIFICATION:-
Ampere loading of Boiler Feed Pumps reduced by 40 A per Boiler Feed Pump.
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Chapter-5
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But when boiler tube is fail then 1000 kiloliter water is waste. The water
used in it is distilling water and it cost is 8 Rs. Per liter. As per market rate.
Another loss is Generation loss which occurs due to starting of Boiler. And
that cost is Rs.1.5 cr.