08 - Erosion Protection Measu 210911

Field Engineering Services
BHEL, Tiruchirappalli-14
Erosion Protection Measures operational Influence
on Tube Metal temperature (Pressure Parts)
Coal is one of the main fuels for power generation. Coal quality
deterioration over the years has created challenges for boiler designers
the world over to fly ash erosion are almost 35% of the total tube
failures. In high ash coal fired boilers. Fly ash erosion is a major concern
and the tube failures due to fly ash erosion are almost 35% of the total
tube failures. The amount of ash in coal and its velocity are major factors
in the rate of pressure part erosion. Fly ash erosion is experienced in the
economizer, primary SH, and inlet section of steam reheater tubes.
When non-uniform flue gas flow distribution occurs in these areas, the
rate of erosion increases multifold.
Factors influencing fly ash erosion in coal fired boilers are
 The velocity of flue gas

 The temperature of flue gas
 The mineral content in coal
 The change in direction of flue gas
 The arrangement of pressure parts and
 The operation above the maximum conditions design rating or with
excess airflow above design rate.
Of these factors, the velocity of flue gas, the temperature of flue gas
(ash), and mineral matter in coal are the main influencing factors.
The velocity of flue gas
For low ash coals, the weight loss in pressure parts due to erosion is
proportional to flue gas velocity to the power of 1.99. However for high
ash coals the erosion rate is velocity to the power of 3 to 5. The power
depends upon the percentage of ash in coal, the percentage of silica in
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coal ash, the percentage of quartz in this silica, the percentage of alpha
quartz in this quartz, and the structure of alpha quartz.
Temperature of flue gas
Higher temperature softens the minerals in the ash as well as reduces

the strength properties of the material of pressure parts; due to this ash
erosion is not predominant in high temperature zones like furnaces, final
super heaters, exit re heaters, etc. The ash erosion mainly starts in the
conventional two-pass boilers from the area where gas temperature is
around 700 to 750°C. The low temperature super heater (LTSH) and
economizer are the areas where ash erosion is severe in a conventional
two-pass boiler. The temperature of flue gas entry to LTSH can be
around 650 to 700 degree C and leaving, the economizer can be around
350 to 300°C. The minerals, which mainly constitute the ash in flue gas
at these temperatures, become hard and attain its full abrasiveness.
Mineral matter in coal
The proportion and composition of the mineral matter in coal will

determine the extent of fly ash erosion that can take place. All the
mineral matter undergoes phase transformation during the process of
combustion of coal in furnace. The phase transformation of the mineral
matter is dependent on various factors like the presence of oxygen
(oxidizing or reducing atmosphere) in the localized area of furnace, the
temperature of the flame / furnace, the retention time, the composition of
the minerals in question, etc.
Measures to Reduce Fly ash Erosion
The following are the areas in boiler where coal ash erosion is normally
experienced.
(i) Economizer bends and tubes
(ii) LTSH bends and tubes
(iii) Screen tubes
(iv) Goose neck portion at furnace top
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(v) Soot blower openings in the water walls
(vi) Wind box opening in the furnace near the burner panel
(vii) Bottom hopper tubes
In the case of Economizer bends and tubes, LTSH bends and tubes and
Screen tubes the erosion is due to ash in the flue gas stream directly
impact and flow over the tube. In the case of Goose neck portion at
furnace top and Wind box opening in the furnace near the burner panel it
is more due to ash collected in this region sliding over the tubes. In the
bottom hopper impact of the water wall deposit is predominant. In the
case of Soot blower openings in the water walls and Wind box opening
in the furnace near the burner panel it is more due to entrained ash / fuel
causing erosion due to eddies formed in this area.
To reduce the erosion in these areas
(a) Reduced gas velocity in second pass
(b) Use Inline arrangement for all second pass heat transfer surface
(c) Provide shield in places prone for higher erosion
(d) Provide cassette baffles for LTSH and economizer bends
(e) Go for refractory lining in areas of high erosion where shields

cannot be provided.
As low grade coals are now emerging to be used in large quantity in

boilers for power generation and process steam requirement, it has
become necessary to protect the pressure parts from ash erosion. It can
be said with confidence that in the case of high ash coals, erosion
cannot be avoided; it can be only minimized to an optimum level.
However data show that the boiler pressure parts in the second pass like
LTSH and Economizer may need replacement in full from about 10-15
years of operation depending upon the nature of the ash, the type of
operating regime maintained, etc.
Page No.3/12

PRESSURE PARTS EROSION PRONE AREAS. FIGURE-1
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PROTECTION OF REFRACTORY LINING AREA. FIGURE-2
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PROTECTION OF REFRACTORY LINING AREA. FIGURE-3
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LTSH COIL EROSION PROTECTION SHIELD ARRGT. FIGURE-4
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EROSION PROTECTION SHIELD FOR WW SCREEN TUBES AND
EXTENDED SWW TUBES. FIGURE-5
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EROSION PROTECTION SHIELD FOR ECO. COIL. FIGURE-6
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EROSION PROTECTION SHIELD FOR EXTD SIDE SCW TUBES.
FIGURE-7
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ECONOMISER ASSEMBLY EROSION PRONE AREA. FIGURE-8
ECONOMISER ASSEMBLY EROSION PRONE AREA. FIGURE-9
Page No.11/12

ECO. ASSY. EROSION PROTECTION SHIELDING. FIGURE-10
Page No.12/12

08 - Erosion Protection Measu 210911

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Field Engineering Services

Factors influencing fly ash erosion in coal fired boilers are

 The velocity of flue gas

The velocity of flue gas

Temperature of flue gas

Higher temperature softens the minerals in the ash as well as reduces

Mineral matter in coal

The proportion and composition of the mineral matter in coal will

Measures to Reduce Fly ash Erosion

(i) Economizer bends and tubes

(ii) LTSH bends and tubes

(iii) Screen tubes

(iv) Goose neck portion at furnace top

(vii) Bottom hopper tubes

To reduce the erosion in these areas

(a) Reduced gas velocity in second pass

(c) Provide shield in places prone for higher erosion

(d) Provide cassette baffles for LTSH and economizer bends

(e) Go for refractory lining in areas of high erosion where shields

As low grade coals are now emerging to be used in large quantity in

ECONOMISER ASSEMBLY EROSION PRONE AREA. FIGURE-9

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