Boiler Tube Failure Report

Boiler # 8, 02.11.16
Report No. : Outage No
:

Date : 18.11.16
1 Station DPL Boiler Size 250MW Capacity
2 Unit no #8 3
Stem Flow 810 TPH

Date Time
Total no of BTF of Total no of BTF BTF first
4
Station (FY)
5 5
of this unit (FY)
1 6 02.11.16 15:30 Hrs
detected

7 Load at Failure 11 Outage Hrs 8 Unit Shut down 02.11.16 15:59 Hrs
Generation Loss Mu 9 Clearance for
12
Light -up
BTF inspected by  10 Unit
13 BTFR Head BM
Synchronization
FQA Operation 
Chemistry O&E
Boiler Tube Failure Location
14 Location of Primary Failure
a Economizer Top Middle Lower Other
b LTSH Top Middle Lower  Other
c SH Divisional Platen Final Other
d Reheater Front Rear Stage no Other
e Furnace WW Front Rear Left Right
Gooseneck Nr Brnr Nr Soot Blower
f Second Pass Wall Front Rear Left Right
 g Extended WW Left Right h Ceiling Roof
I Drains/Vents j Hanger Tube Steam Hanger Tube Water
K Screen Tube Steam Screen Tube Water
15 Coordinates of the Failed Location
33,34,35, Panel no: 33(tube no 1 & 2 failed due to
A Panel No From Left Elevation (MR) 44 steam washing),Panel no: 34( tube no 1
36,37
From Right & 3 failed due to steam washing, tube
no 2 failed due to overheating appeared
Tube No From Top - 33(1,2), From Front From Left
as Fish mouth), Panel no: 35(tube no 1
34(1,2,3), & 2 failed due to puncture), Panel no:
C 35(1,2), 36(tube no 1failed due to puncture, tube
36(1,2), no 2 failed due to to overheating
37(1,2). appeared as window opening), Panel no:
From Bottom From From Right 37(tube no 1 & 2 failed due to steam
Rear washing)
From From
D Distance along the Failed Tube in Meters
Front Left
From From
Rear Right

16 Weld Failure Occurred at

Maint. Joint
Shop Joint
Support Spacer Membra
17 Attachment Failure Occurred at
ne
Tie weld Seal Others
18 External Description of Failed Tube
a Thin edged Fracture h Blister apperance o Oxide Coated Fracture Surface
b Thick edged Fracture I Gouged Appearance p Severe Localized Deformation
Crazed Crack
c Longitudinal Fracture  j q Other
Appearance
d Circumferential Crack Alligator hide
k
appearance
e Pinhole Fracture l Thick edged crack
Window opening 
f m Hard dark ash deposits
Fracture
Fish mouth  Flat spots adj. to
g n
appearance Fracture
19 Internal Description of Failed Tube
a Thick Deposits c Red Rusty Appearance e Gouged Appearance
Crater Like
b d Heavily Etched Surface f Other
Appearance

Primary Failure Mechanism

20 A: External Erosion
a Fly Ash c Mechanical Rubbing e Soot Blower
b Falling Slag d Coal Particle
 Long Term/ Hi-
B: Over Heating a Short Term b
temp Creep
Acid/Phosphate
C: Corrosion a Stress Corrosion b
corrosion
c Lo-Temp Corrosion Fire Side Corrosion
d e
(WW/SH/RH) Caustic Gouging
f Hydrogen Damage g Pitting
D: Fatigue b Thermal c Corrosion
a Vibration
E: Weld Defect
a Shop Joint b Erection c Maintenance
F:Material Defect
 Boiler Tube Failure Report (C-2 Form)
G: Maintenance
Damage

21 Original Tube OD mm 47.63 Thickness 5 mm Material SA210 Gr C

Dimension
22 Failed Tube OD mm 47.63 Thickness 5 mm Material SA210 Gr C
Dimension
23 Suspected Root Cause Short term overheating
of Primary Failure
24 Secondary Tubes Steam washing
Failed
(To be filled by Chemistry Group only)
25 Chemical Parameters PH Hydrazine
Maintained during
preservation of Boiler:

26 LP Dosing was used during Light -up

27 CPU was taken in to service during
start -up

Signature :