VIZAG BED COIL REPLACEMENT

PREPARED BY: PRADYUMNA KUMAR SAHOO

ESSAR POWER ORISSA LIMITED

20041124
 BOILER BED COIL

WHY BED COIL IS NEEDED?

 It is required to maintain the temperature of the fluidizing bed at around 900°C.

 Bed temperature is maintained by transferring heat of the bed to the feed water quickly,
for this these are placed inside the fluidizing bed.
 These coils act as evaporator coils and cool down the bed.

CAUSES OF BED COIL FAILURE.

Leakage of the tube may take place due to following reasons,

 Scaling
 Erosion
 Corrosion

Other than the above reasons are

PITTING:

 Oxygen presence in feed water reacts with boiler tube metal to form iron oxide. Results the
tube internals surface is corroded in deep groove spots called pitting.
 This can happen in running condition due to excessive oxygen in feed water or due to
improper passivation.
 It is normally observed near economiser feed water inlet area on running boiler and due to
improper passivation this can be observed at non drainable surface.

STRESS CORROSION CRACKING:

 Cracks take place where combination of high tensile stress and corrosion fluids are present.
 Cracks may be trans granular or inter granular in the tube wall.
 Normally it is observed near higher external stresses like attachments
 BED COIL REPLACEMENT PROCEDURE

PROCEDURE:

 First of all the manhole door are opened then the start up oil firing system was disconnected
from boiler.

MAN HOLE DOOR OPENED

DEISEL LINE

PA LINE

START UP OIL FIRING SYSTEM -OPENED CONDITION

 BOILER INSULATION AND REFRACTORY MATERIALS REMOVED OUT AND OLD BED COILS ARE
CUT DOWN.

INSULATION REMOVAL REFRACTORY REMOVAL

BED COIL CUTTING

BED COIL CUT DOWN

 After cutting the bed coils, stubs are sealed by brown tape or dummy cover then boiler
cleaning is done.
 After cleaning , grinding operation started on the stub ends & again it was covered by the
dummy.
 Weld edge preparation is done by using a chamfering m/c on the stub.

BEVEL EDGE

DUMMY COVER

STUB/TUBE

CHAMFERING M/C
 The bed coil tubes are cleaned by service air (4kg/cm2) with the help of
polyurethane sponge. It is used minimum 3 times for better cleaning.
 A temporary clamp was made to hold up the bed coil for fit up.
 Now the alignment procedure starts-
o First of all they got the centre between the top ring header and bottom ring header.
o Then the level of centre line and bed coil centre was checked. (It means the centre
line of the headers and bed coil should be in same level). water level used for
checking the level.
o After that they clamped the inner bed coil by the clamp, making a gap of 2-3 mm
between the stub and bed coil edge by the help of welding rod.

CLAMP

WELDING ROD

BOILER BED COIL ALIGNMENT

 TOP HEADER

INNER BED COIL

CENTRE LINE
OUTER BED COIL

BOTTOM HEADER

o After tech weld the clamp was removed and then fill up/full welding was done.

Welding specification:

ROOT WELDING FILL UP/ FINAL WELDING

TUNGSTEN INERT GAS WELDING (TIG) SHIELDED METAL ARC WELDING (SMAW)

ELECTRODE USED-TUNGSTEN ELECTRODE USED-E 7018

FILLER ROD USED-ER70S2

SHIELDING GAS-ARGON-CO2 MIX

o A “T” rod was made to measure the distance between bed coils to bed coil.

A=B (STUB TO STUB DISTANCE)

o To ensure the vertical height of bed coils, a string was holding by two workers. Then the
vertical height is measured by a plumb.
o After checking height of all bed coils, it is declared that the bed coil replacement done. Then
radiography of all joint done.