Residual Life Assessment

and
Life Extension Programme
In Power Boilers
of Captive Power Plant of NALCO

By
R.S.DAS, Chief Manager (MECH),CPP,NALCO

R.S.DAS,NALCO

BRIEF ABOUT NALCO

(National Aluminium Company Ltd)
National Aluminium Company is an integrated
aluminium producing Public Sector Company
under Govt . Of India with Bauxite Mines,
Alumina Refinery Plant, Smelter Plant, Captive
Power Plant and Port Facility situated at different
locations of Orissa and Andhra Pradesh .

R.S.DAS,NALCO

PRESENT STATUS OF THE COMPANY

METAL PRODUCTION CAPACITY: 3.45 lakh tones per annum
NO OF METAL PRODUCING POTS: 720
POWER CONSUMED BY THE POTS : 576 MW
POWER GENERATING CAPACITY : 8 X 120 = 960 MW
BOILER CAPACITY: 430 T/HR ( unit-1 -6),
390T /HR( unit-7 & 8)
BOILER TYPE:
BALANCED DRAFT,NATURAL CIRCULATION,PULVERISED COAL,
CORNER FIRED,WATER TUBE,REHEAT TYPE

R.S.DAS,NALCO

120 MW X 8
R.S.DAS,NALCO

RAW WATER

HP
HEATER

D/A

LP HEATER

GRIDCO

BFP

WATER TREATMENT
HPT

IPT

LPT

GENERATOR
SMELTER

COOLING
TOWER

10.5 KV

220 KV

CEP
CW PUMP

6.6 KV
UA T

CONDE NSER
REHEA TED S TEAM

GT

6.6 KV
SAT

CONDENSATE
STORAGE TA NK

CHIMNEY

BOILER
COAL B UNKERS
ECONOMISER
ELECTRO STA TIC
PRECIPITA TOR
FUEL OIL TA NK

MILL

ID FAN
FD FANS
PA FAN

COAL

CRUS HER
ASH SLURRY PUMPS

R.S.DAS,NALCO

Requirement of Residual Life Assessment

Study (RLA )
To assess the present condition of the
boiler pressure parts
To assess the remaining life of the Boiler
Pressure parts
Statutory requirement as per IBR
regulation 391A

R.S.DAS,NALCO

RLA Study of Boiler is a statutory requirement as per regulation 391A

of Indian Boiler Regulation-1950, which says:1.

The Boilers which are operating at a temperature of 400oC & above

including utility or industrial boilers & all boiler parts operating in
the creep range of boiler shall be non-destructively tested as per
Table-1, after they are in operation for 1,00,000 hours for
assessment of the remnant life of parts.

2.

The parts of a boiler when it completes a life of 25 years are to be

tested as per Table-2 for assessment of remnant life of such parts.
If results are acceptable as per the standards laid down by the
Central Boiler Board, a certificate shall be issued by the Chief
Inspector of Boilers for extending the life of boiler for a further
period of 10 years or such less period as recommended by the
Remnant Life Assessment Organisation. The remnant life shall be
carried out thereafter every five years by approved parties by the
Central boiler board.
R.S.DAS,NALCO

PURPOSE OF RLA STUDY

z

Evaluation of present condition of pressure

parts & piping
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
R.S.DAS,NALCO

RLA STUDY IN CAPTIVE POWER PLANT, NALCO

UNIT
2(part RLA of RH)

YEAR
1997

2000

2003

2004

2004

2005

2009( DUE)

2015( DUE)

2016(DUE)
R.S.DAS,NALCO

Methodology adopted for Residual Life

Assessment in NALCO,CPP By M/S BHEL

Review of the past data

Field Visual and dimensional inspection
UT
DP
Hardness Measurement
Replication for Metallography
Inside oxide scale thickness measurement
Video Scopic Examination
Tube Sampling
Laboratory testing
Recommendation and life prediction

R.S.DAS,NALCO

10

TIME PERIOD FOR THE STUDY : 10 TO 12 DAYS

PRELIMINARY REPORT SUBMITTED IMMEDIATELY

AFTER THE STUDY

THE FINAL REPORT WITH RECOMMENDATION

SUBMITTED WITHIN 5 TO 6 MONTHS TIME.

TEAM MEMBERS : 12 INCLUDING ONE TEAM LEADER

R.S.DAS,NALCO

11

Tests Done during RLA Study of our

Boilers
High temperature headers & piping
Ultrasonic, dye-penetrant tests
Video scope, Replication
Other inspections like
Dimensions,
Internal inspection
Insitu hardness
R.S.DAS,NALCO

12

Tests Done during RLA Study of our

Boilers (Cont. )
Superheater & reheater tubes
Tube samples, ultrasonic test
OD & Thickness
Deposit Analysis
Steam side oxide scale thickness
Life prediction
Attemperators
Ultrasonic, dye penetrant tests
Replication, hardness
Fiber optics
R.S.DAS,NALCO

13

Tests Done during RLA Study of our

Boilers

(Cont. )

Furnace & convection pass tubes

Tube sampling, ultrasonic test
Deposit analysis (Internal & External)
Drums & downcomers
Ultrasonic, dye-penetrant tests
MPI (Wet fluorescent & Dry)
Video scope

R.S.DAS,NALCO

14

Tests Done during RLA Study of our

Boilers (Cont. )
STEAM PIPING( MS,CRH,HRH & FW)
Visual Inspection
Replication, Insitu Hardness
OD & thickness
Hangers & Supports Inspection
General guidelines for selecting inspection points
High turbulence or velocity
Condensation points
Dead ends & high stressed points
Areas immediately downstream of chemical
injection points
All supports
R.S.DAS,NALCO

15

DIMENSIONAL MEASUREMENT AT CPP NALCO DURING

RLA

R.S.DAS,NALCO

16

DP TEST ON CRITICAL PIPING JOINTS AT CPP ,NALCO

R.S.DAS,NALCO

17

DRUM INSPECTION AT CPP,NALCO

R.S.DAS,NALCO

18

HANGER
CHECKING AT
CPP ,NALCO

R.S.DAS,NALCO

19

IN SITU REPLICATION ON MS PIPE

R.S.DAS,NALCO

20

MICROSCOPIC EXAMINATION DURING REPLICATION

AT CPP ,NALCO

R.S.DAS,NALCO

21

INTERNAL OXIDE SCALE MEASUREMENT AT CPP ,NALCO

R.S.DAS,NALCO

22

IOT AT CPP ,NALCO

PROBE

R.S.DAS,NALCO

23

VIDEO SCOPE AT CPP BOILER ,NALCO

BOTTOM RING
HEADER

R.S.DAS,NALCO

24

VIDEO SCOPE OF
SH HEADER

STUB

R.S.DAS,NALCO

25

TUBE SAMPLING AND LABORATORY TESTING

TUBE SAMPLES WERE COLLECTED FROM DIFFERENT
ZONES OF OUR BOILERS FOR LABORATORY TESTING
1. WATER WALL- 04 NO
2. PLATEN SH- 02 NO
3. CRH- 02
4. RH INTER BANK-02
5. HRH-02
6. LTSH-02
7. ECO-01
R.S.DAS,NALCO

26

Laboratory testing included the

following
Visual Examination
Dimensional measurement
Chemical composition analysis
Flattening test for water wall tubes
Hardness measurement
Steam side oxide scale thickness measurement
Micro examination of all the tube samples and
insitu replicas ( 30 no) for spheroidisation level of
PM,WELD &HAZ and creep level( PM only)
Internal deposit analysis of water wall tubes and
Boiler Drum
Creep rupture testing for rupture life of Platen SH
& RH coil tubes
R.S.DAS,NALCO

27

General Recommendations Format of RLA

FOR CPP, NALCO BY BHEL
Residual life of RH and SH coil tubes
Creep and Spheroidisation level of pressure part
components
Parts needing replacements
Parts needing repairs
Chemical cleaning advice & procedure
Advice on water regimes
Future plans of tests
Modifications required for life extension
Any other specific observations
R.S.DAS,NALCO

28

INTERNAL DEPOSIT ANALYSIS

The internal deposit analysis of water wall and
Drum (quantity and composition) were done for
all the units .
Norms of our OEM (BHEL)
< 15 mg/cm2 Clean
15-40 mg/cm2 Moderately clean
>40mg/cm2

Very dirty

All our boilers were found in the moderately clean

zone after the deposit analysis.
No immediate chemical cleaning was recommended.
R.S.DAS,NALCO

29

Life Prediction Techniques Used

By using appropriate damage parameter
Using strain measurements
Post exposure testing
Using Steam Side Oxide scale thickness

R.S.DAS,NALCO

30

R.S.DAS,NALCO

31

Life prediction based on Oxide Scale

Thickness Analysis
The steam side oxide scale thickness are measured at
critical locations in the high heat flux zone and near the
bottom bends of the super heater and re heater coils.
These values are used as inputs to computer-based
software BHELMOLT which accurately calculates the
tube metal temperatures for the entire cross-section of
tubes and calculates the residual life .

R.S.DAS,NALCO

32

Oxide Scale Thickness Analysis

DATA INPUT TO THE SOFTWARE
ORIGINAL TUBE OD
ORIGINAL TUBE THICKNESS
MATERIAL
SERVICE HOURS
PRESSURE
OXIDE SCALE THICKNESS
MINIMUM TUBE THICKNESS
MINIMUM TUBE OD

R.S.DAS,NALCO

33

OUT PUT
TOTAL RUPTURE LIFE
REMAINING LIFE

R.S.DAS,NALCO

34

COILWISE OXIDE SCALE THICKNESS OF REHEATER

COIL WISE OXIDE THICKNESS
1.4

OXIDE THICKNESS IN MM

1.2

0.8
OXIDE THICKNESS
0.6

0.4

0.2

0
1

11

13

15

17

19

21

23

25

27

29

31

33

35

37

39

41

43

45

47

COIL NO

R.S.DAS,NALCO

35

COIL WISE TEMP

640

COIL WISE
SERVICE TEMP.

TEMPERATURE IN DEGREE

620

600

580
TEMP
560

540

520

500
1

11 13 15

17 19 21

23 25 27

29 31 33

35 37 39

41 43 45

47

COIL NO

COIL WISE REMAINING LIFE IN HRS

180000
160000

REMAINING LIFE IN HR

140000
120000
100000
REMAINING LIFE IN HRS
80000

COIL WISE
REMAINING LIFE.

60000
40000
20000
0
1 3 5

7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47
COIL NO

R.S.DAS,NALCO

36

POST EXPOSURE TESTING

The sample tubes, removed from Boiler SH and RH are
subjected to burst tests at accelerated temperature and
service pressure in the hot burst rig facility available at
BHELs laboratory. The pressure and temperature are
controlled very accurately.
To predict the remaining life from the results of
stress rupture tests, the following methods are adopted.
1. Parametric extrapolation
2. Application of Life fraction rule

R.S.DAS,NALCO

37

R.S.DAS,NALCO
EXTRAPOLATED
LIFE OF SH COIL

38

LIFE PREDICTION
LIFE PREDICTION OF OUR RH AND PLATEN SH TUBES
WAS DONE BASED ON INSIDE OXIDE SCALE THICKNESS
MEASUREMENT.
IN UNIT-2 , 37 NO RH COILS WERE REPLACED IN 2001
BASED ON LIFE PREDICTION DONE IN 1997.
IN UNIT-1 , 34 NO RH COILS WERE REPLACED IN 2005
BASED ON LIFE PREDICTION DONE IN 2000.
IN OTHER UNITS THE PREDICTED LIFE OF RH AND SH
COILS ARE AS BELOW.

R.S.DAS,NALCO

39

PREDICTED LIFE OF RE HEATER TUBES

DESCRIPTION

PREDICTED LIFE

UNIT-3 RH AND PLATEN SH

COIL TUBES

MORE THAN 1 LAKH HOUR

UNIT-4 PLATEN SH

MORE THAN 1 LAKH HOUR

UNIT -4 HRH coil Coil 30 fifth

ckt rear

54,500 Hrs

Unit-4 HRH Coil 32 fifth ckt rear

47,500 Hrs

Unit-4 HRH Coil 33 fifth ckt rear

56,500 Hrs

Unit-4 all other RH coils

MORE THAN 1 LAKH HOUR

Unit-5 HRH Coil 22 fifth ckt rear

59,100 Hrs

Unit-5 HRH Coil 31 fifth ckt rear

56,100 Hrs

Unit-5 HRH Coil 33 fifth ckt rear

66,100 Hrs

R.S.DAS,NALCO

40

PREDICTED LIFE OF SUPER HEATER TUBES

DESCRIPTION

PREDICTED LIFE

UNIT-1 PLATEN SH COIL

TUBES

MORE THAN 2 LAKH HOUR

UNIT-2 PLATEN SH COIL

TUBES

MORE THAN 1 LAKH HOUR

UNIT-3 PLATEN SH COIL

TUBES

MORE THAN 1 LAKH HOUR

UNIT-4 PLATEN SH COIL

TUBES

MORE THAN 1 LAKH HOUR

UNIT-5 PLATEN SH COIL

TUBES

MORE THAN 1 LAKH HOUR

R.S.DAS,NALCO

41

Creep Cavity Level Classification System

Proposed by Wedel & Neubauer

R.S.DAS,NALCO

42

CREEP AND SPHEROIDISATION LEVEL

THE CREEP AND SPHEROIDISATION LEVEL OF
ALL THE PRESSURE PARTS WERE ANALYSED BY
BHEL EXPERTS.
NO MAJOR ABNORMALITIES WERE FOUND IN
MOST OF THE CASES.
ONLY IN UNIT-3 ISOLATED CREEP CAVITIES
WERE OBSERVED ON THE GRAIN BOUNDARIES
OF MS PIPE LINE . BHEL SUGGESTED FOR REEXAMINATION AFTER THREE YEARS WHICH IS
TO BE DONE IN 2008.

R.S.DAS,NALCO

43

SUMMARY OF THE OBSERVATIONS OF RLA STUDIES OF DIFFERENT UNITS

SL
.
N
O.

AREA OF
THE
BOILER PR
PARTS

01.

RLA Study of
Boiler after
1,00,000 Hrs.
of Operation

Done in
August 2000

Done in
December
2003

02.

Boiler Drum
- Visual
-Insitu Replica
-Hardness
-UT
-DP
- Deposit
analysis

No specific
recommendatio
n and found o.k

03.

Water Wall
-Visual
-Sampling(
internal
deposit and
hydrogen
embrittlement)
- Dimensions
( OD &
thickness)

No specific
recommendatio
n and found o.k

UNIT # 1
(OR-369)

UNIT #2
(OR-370)

UNIT # 3
(OR-372)

UNIT
#6
(OR513)

UNIT
#7
(OR696)

UNIT
#8
(OR713)

UNIT # 4
(OR-382)

UNIT # 5
(OR-397)

Done April
2004

Done in July
2004

Done in June2005

Not
due
(runnin
g hrs <
100000
)

Not
due
(runnin
g hrs <
100000
)

Not
due
(runnin
g hrs <
100000
)

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

NA

NA

NA

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

NA

NA

NA

R.S.DAS,NALCO

44

SL.
NO
.

AREA OF
THE BOILER
PR PARTS

UNIT # 1
(OR-369)

UNIT #2
(OR-370)

UNIT # 3
(OR-372)

UNIT # 4
(OR-382)

UNIT # 5
(OR-397)

UNIT #
6 (OR513)

UNIT #
7 (OR696)

UNIT #
8 (OR713)

04.

Eco Coils;
- Visual
-Dimensional
checks,
-Sample check
for
metallography

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

NA

NA

NA

05.

Low tem
Header ( Eco
in and
out,Bottom
ring header );
- Visual
-Fibrovision
Inspection
-Hardness
-DP
-Dimensions

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

NA

NA

NA

06.

LTSH Coils;
- Visual
- Hardness
-Dimensional
checks,
-Sample check
for
metallography

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

NA

NA

NA

R.S.DAS,NALCO

45

SL.
NO
.

AREA OF
THE BOILER
PR PARTS

UNIT # 1
(OR-369)

UNIT #2
(OR-370)

UNIT # 3
(OR-372)

UNIT # 4
(OR-382)

UNIT # 5
(OR-397)

UNIT #
6 (OR513)

UNIT #
7 (OR696)

UNIT #
8 (OR713)

07.

LTSH Outlet
Header ( SHH
9 );
- Visual
-Fibrovision
Inspection
-Insitu Replica
-Hardness
-UT
-DP
-Dimensions

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

NA

NA

NA

08.

SH Inlet
Header ( SHH
10 );
-Fibrovision
Inspection
-Insitu Replica
-Hardness
-UT
-DP
-Dimensions

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

NA

NA

NA

R.S.DAS,NALCO

46

SL.
NO
.

AREA OF THE
BOILER PR PARTS

UNIT # 1
(OR-369)

UNIT #2
(OR-370)

UNIT # 3
(OR-372)

UNIT # 4
(OR-382)

UNIT # 5
(OR-397)

UNI
T#
6
(OR
513)

UNI
T#
7
(OR
696)

UNI
T#
8
(OR
713)

09.

SH Outlet Header (
SHH 11 );
-Fibrovision
Inspection
-Insitu Replica
-Hardness
-UT
-DP
-Dimensions

No specific
recommendation
and found o.k

No
specific
recommendati
on and found
o.k

No specific
recommendation
and found o.k

No
specific
recommend
ation and
found o.k

No specific
recommendation
and found o.k

NA

NA

NA

10.

Platen SH Coil
-IOT Measurement
-DP
-Dimension check,
-Samples for Creep
rupture &
Metallography Test.
- Hardness

Predicted life :
> 2,00,000 hrs

Predicted
life :
> 1,00,000 hrs

Predicted life :
> 1,00,000 hrs

Predicted
life :
> 1,00,000
hrs.

Predicted life :
> 1,00,000 hrs.

NA

NA

NA

11.

Desuperheater :-Fibrovision
Inspection.
-Insitu Replica
-Hardness
-UT
-DP
-Dimension check

No specific
recommendation
and found o.k

No specific
recommendati
on and found
o.k

No specific
recommendation
and found o.k

No specific
recommend
ation and
found o.k

No specific
recommendation
and found o.k

NA

NA

NA

R.S.DAS,NALCO

47

SL.
NO
.

AREA OF THE
BOILER PR PARTS

UNIT # 1
(OR-369)

UNIT #2
(OR-370)

UNIT # 3
(OR-372)

UNIT # 4
(OR-382)

UNIT # 5
(OR-397)

UNI
T#6
(OR513)

UNI
T#
7
(OR696)

UNI
T#
8
(OR713)

12.

Reheater Inlet Header

( RHH 1 )
-Fibrovision
Inspection
-Insitu Replica
-Hardness
-UT
-DP
- Dimensions

No specific
recommendation
and found o.k

No
specific
recommendatio
n and found o.k

No specific
recommendation
and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendation
and found o.k

NA

NA

NA

13.

Reheater Outlet
Header ( RHH 2 )
-Fibrovision
Inspection
-Insitu Replica
-Hardness
-UT
-DP
- Dimensions

No specific
recommendation
and found o.k

No
specific
recommendatio
n and found o.k

No specific
recommendation
and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendation
and found o.k

NA

NA

NA

14.

Reheater Coil :-IOT Measurement

-Samples for Creep
rupture &
Metallography Test
-Dimension check.
-Hardness

Replacement of
Reheater Coils
(25 - 48) from
Interbank outlet
to HRH outlet
header; ( RLA :2000, Aug ) .
Action taken :
Reheater Coils
(15 - 48) from
Interbank outlet
to HRH outlet
header were
replaced in
May 2005.

Predicted life:
i) Front coils >
95,000 hrs
ii) Rear coils >
1,00,000 hrs

Predicted life :
> 1,00,000 hrs

Predicted life :
1. > 1,00,00 for
all coils except
HRH coil
30,.32,33 in the
fifth ckt rear.
2. Coil 30 fifth
ckt rear54,500 hrs,
3. Coil 32 fifth
ckt rear47,500 hrs
4. Coil 33 fifth
ckt rear56,500 hrs,

Predicted life :
1. > 1,00,00 for
all coils except
HRH coil
22,31,33 in the
fifth ckt rear.
2. Coil 22 fifth
ckt rear- 59,100
hrs,
3. Coil 31 fifth
ckt rear- 56,100
hrs
4. Coil 33 fifth
ckt rear- 66,100
hrs,

NA

NA

NA

R.S.DAS,NALCO

48

SL.
NO
.

AREA OF THE
BOILER PR PARTS

UNIT # 1
(OR-369)

UNIT #2
(OR-370)

UNIT # 3
(OR-372)

UNIT # 4
(OR-382)

UNIT # 5
(OR-397)

UNI
T#
6
(OR
513)

UNI
T#
7
(OR
696)

UNIT
#8
(OR713)

15.

a) MS Pipe line :-Insitu Replica

-UT
-DP
-Dimension checks.

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendati
on and found
o.k

NA

NA

NA

Reexamination
in 2008

b) HRH Pipe line :-Insitu Replica

-UT
-DP
-Dimension checks.

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendati
on and found
o.k

NA

NA

NA

c) CRH Pipe line :-Insitu Replica

-UT
-DP
-Dimension checks.

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No
specific
recommendati
on and found
o.k

NA

NA

NA

d) MS Pipe line from

MS-1 & MS-2
up to Turbine stop
valve.
-Insitu Replica
-UT
-DP
- Dimension
checks.

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

Reexamination
in 2008

No specific
recommendatio
n and found o.k

No
specific
recommendati
on and found
o.k

NA

NA

NA

e) HP Bypass Pipe
line
-Insitu Replica
-UT
-DP
-Dimension checks.

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No specific
recommendatio
n and found o.k

No
specific
recommendati
on and found
o.k

NA

NA

NA

R.S.DAS,NALCO

49

AREA OF THE
BOILER PR PARTS

UNIT # 1
(OR-369)

UNIT #2
(OR-370)

UNIT # 3
(OR-372)

UNIT # 4
(OR-382)

UNIT # 5
(OR-397)

UNIT # 6
(OR-513)

UNIT #
7 (OR696)

UNI
T#
8
(OR
713)

f) Feed water Pipe

line
-Insitu Replica
-UT
-DP
-Dimension checks.

No specific
recommenda
tion and
found o.k

No specific
recommend
ation and
found o.k

No specific
recommendatio
n and found o.k

No specific
recommen
dation and
found o.k

No specific
recommen
dation and
found o.k

NA

NA

NA

16
.

RLA Study of Boiler

after 1 lakh hrs of
Operation

DONE

DONE

DONE

DONE

DONE

2009

2015

2016

17

Compete RLA Study

of Boiler after 25
Years of Operation

2008

2009

2009

2009

2010

S
L.
N
O
.

R.S.DAS,NALCO

50

BENEFITS OF RLA STUDIES IN CPP NALCO

A THOROUGH CHECK OF ALL THE PRESSURE PARTS,CRITICAL PIPE LINE
AND HANGER SUPPORTS COULD BE MADE.
THE SPHEROIDISATION LEVEL AND CREEP LEVEL OF THE PRESSURE PARTS
INCLUDING THICK WALLED COMPONENTS LIKE DRUM, ALL HEADERS,
PIPE LINES COULD BE ASSESSED.
THE LIFE OF THE PLATEN SUPER HEATER AND REHEATER TUBES COULD BE
PREDICTED.
THE DEPOSIT INSIDE AND OUT SIDE OF THE TUBES COULD BE ANALYSED.
THE CONDITION OF THE HANGERS COULD BE ASSESSED AND REMEDIAL
ACTION COULD BE TAKEN.
CORRECTIVE AND PREVENTIVE MEASURES LIKE TIMELY REPLACEMENT
OF RH COILS IN UNIT-1( 34 NO) AND 2 (37 NO) COULD BE INITIATED.
PLANT AVAILABILITY HAS BEEN INCREASED BY TIMELY REPLACEMENT OF
PRESSURE PARTS.
OPERATING PARAMETERS ARE NOW BETTER CONTROLLED AND
TEMPERATURE EXCURSIONS ARE ELEMINATED.

R.S.DAS,NALCO

51

EXPENDITURE FOR RLA STUDIES IN CPP

NALCO
(VALUE OF THE CONTRACTS ON BHEL)
UNIT-1 : 20.5 LAKH
UNIT-2 &3 : 20.5 LAKH X 2
UNIT-4 &5 : 20.00 LAKH X 2

R.S.DAS,NALCO

52

RH TUBE FAILURE IN UNIT-2

7
6
5
4
3

NO

2
1
0
1988-2002

2002-07
YEAR

R.S.DAS,NALCO

53

RH TUBE FAILURE IN UNIT-1

6
5
4
3

NO

2
1
0
1988-2002

2002-07
YEAR

R.S.DAS,NALCO

54

LIFE EXTENSION MEASURES IN THE BOILERS OF NALCO

CAPTIVE POWER PLANT
1.FITMENT OF PROTECTIVE SHIELDS IN EROSION
PRONE AREAS LIKE ECONOMISER TUBES , BENDS AND
LOW TEMPERATURE SUPER HEATER HEADERS,SCREEN
TUBES,WATER WALL S PANEL ( TOP OF QUENCHING
NOZZLE)
2. FITMENT OF 6 MM SS RODS IN THE BURNER PANEL
TUBES TO DIVERT THE SECONDARY AIR THUS
PREVENTNG EROSION

R.S.DAS,NALCO

55

3.GANGING OF ECONOMISER COILS TO MAKE ECO COIL

SPACING UNIFORM.
4.REPLACEMENT OF TUBES ON THE BASIS OF
THICKNESS MEASUREMENT
5. SETTING SOOTBLOWER STEAM BLOWING POSITION
7MM MORE THAN THE DESIGNED VALUE TO MINIMISE
STEAM EROSION
6. REPLACEMENT OF REHEATER TUBES ON THE BASIS
OF VISUAL INSPECTION OF FIRE SIDE OXIDE SCALES
AND THICKNESS CHECKING OVER A LONGER SPAN OF
THE TUBES(NEAR TO THE ROOF)
7. METAL SPRAYING(TAFA) WAS TRIED OVER SOME
EROSION PRONE PRESSURE PARTS EXPERMENTALLY.
R.S.DAS,NALCO

56

TREND OF TUBE FAILURES DUE TO ASH,SEC AIR,STEAM

EROSION UPTO 31.3.2007
10
9
8
7

NO

6
5
4
3
NO OF TUBE LEAKAGES

2
1
0
92-93 93-94 94-95 95-96 96-97 97-98 98-99
NO OF TUBE LEAKAGES

99-

2000- 2001- 2002- 2003- 2004- 2005- 2006-

2000

01

02

03

04

O5

06

07

YEAR

R.S.DAS,NALCO

57

TREND OF TUBE FAILURES IN BOILER

16
14
12

NO

10
8
6

4
2
0

NO OF FAILURES

9192

9293

9394

9495

9596

9697

9798

9899

10

12

99- 2000- 2001- 2002- 2003- 2004- 2005- 20062000 01

02
03
04
05
06
07
9

10

15

14

12

YEAR
NO OF FAILURES

R.S.DAS,NALCO

58

OUR FUTURE PLANNING

INSIDE OXIDE SCALE THIKNESS MEASUREMENT OF
RE HEATERS & SUPER HEATERS DURING ANNUAL
OVERHAULING SO THAT REPLACEMENT CAN BE
DONE ON REGULAR BASIS TO REDUCE BREAK DOWN.
INTERNAL CORROSION MAPPING OF BOILER TUBES
METAL SPRAYING OVER EROSION PRONE AREAS
RLA OF BOILERS WHICH HAVE RUN FOR MORE THAN
25 YEARS
MAJOR REPLACEMENT OF COILS /TUBES BASED ON
RLA STUDIES
R.S.DAS,NALCO

59

Thank You

R.S.DAS,NALCO

60