RESIDUAL LIFE ASSESSMENT &

FAILURE OF BOILERS
BY
B. MAHESH (13481A0315)
D.AVINASHYADAV (13481A0342)
B.NIKHIL (13481A0325)
CH.SURESH (13481A0339)
S.VAMSI KRISHNA (12481A03D5)

UNDER THE GUIDANCE OF

Smt. M.KRISHNA PRASANNA M.E
ASSISTANT PROFESSOR

MECHANICAL ENGINEERING DEPARTMENT

 Abstract

The study involved in this project is concerned with RESIDUAL LIFE

ASSESSMENT AND FAILURES OF BOILER.
In the power plant, the boiler operates in a very hostile environment due to
which the boiler tubes are highly prone to failure. If any failure occurs in the
boiler, It will lead to decrease the output of the power plant.
This study is concerned with various techniques involved to study the residual
life of power plant components which are operating at very high pressure and
temperatures.
While two different approaches are available for residual life assessment of
power plant components, one using data analysis operational history and the
other based on periodic examination of critical components, the later method is
widely adopted as it is more accurate since it does not rely on standard material
data with their associated uncertainties and does not necessarily required
knowledge of the operational stress temperature data
 Introduction
The electricity has become an essential commodity rather than luxury now a
days in a state or region thermal power stations will become important, as hydro
resources are inadequate. The concept of a modern thermal power station is that
it should be situated at such a place that the basic requirements of fuel, water and
land should be satisfied.
Basically thermal stations are of two types.
1. Pit head stations
2. Load Demand Stations
Pit head stations are those which are nearer to the source of fuel and
load demand stations are those which are nearer to load centres.
 Principle of operation
The fundamental forms of energy with which thermal station mainly concerned
are heat and work. Heat produces the work then the work is converted into
electricity through a medium i.e. Electrical generator. Thermal power plants
mainly working on the three following cycles
1. Rankine cycle
2. Reheat cycle
3. Regeneration
Types of Failure
1) Rupture 4) Erosion
Fly ash erosion
Short term overheating
Falling slag erosion
High temperature creep
Dissimilar metal welds Soot blower erosion

2) Water side corrosion 5) Fire side corrosion

Caustic corrosion Low temperature corrosion
Hydrogen damage Water wall corrosion
Pitting Coal ash corrosion
Stress corrosion cracking
Flow assisted corrosion
6) Lack of Quality Control
3) Fatigue Maintenance cleaning damage
Vibration Chemical damage
Thermal Material defects
Corrosion Welding defects
1) Short Term Overheating 2) High Temperature Creep

High temperature creep leads to stress rupture of boiler tubes as shown in Fig: 2.
Causes for such failures are partial chocking of tube, general blockage, incorrect
material, material transition, and higher stress due to weld attachment.

The short term overheating leads to stress rupture of the tube as shown in Fig: 1
Causes of short term overheating are Formation of debris and scale on the steam/
water tube, high heat transfer rate or improper firing and Low water/steam level
due to poor circulation.
3) Dissimilar Metal Welds 4) Long Term Overheating
(LTOH)

Dissimilar metal welds causes rupture of Boiler tubes as shown in Fig: 3.This type
of failure mainly occurs due to use of dissimilar metal rods for welding the tube. The
prime location of dissimilar metal welds failures are super heater, Reheater
dissimilar weld joints.

.Tube failed due to LTOH is as shown in Fig: 4. Long term overheating occurs due to
Selection of incorrect material, Scale formation inside the tube, Water side deposits.
Caustic Corrosion Hydrogen Damage

As shown in Fig: 5, the boiler tube failed due to caustic corrosion, it arises due Feed
water system. corrosion deposits, condenser tube leakage, higher concentration of
NaOH in Boiler water and temperature increase due to internal deposits.

This type of damage as shown in Fig: 6 may results from low PH corrosion
reaction which results in the production of atomic hydrogen. NaOH removes
protective magnetic iron oxide layer Fe3O4. Iron reacts with water or NaOH
liberating atomic hydrogen. Atomic hydrogen differs into iron oxide
producing methane. Methane or Atomic hydrogen cannot disposes it, resulting
in cracks of grain boundaries longitudinal bars occurs with thick tip.
Fatigue Failure Fly Ash Erosion

Tube failed due to fatigue is as shown in Fig: 7. Fatigue failure of tubes arises due to
improper flexibility, attachment weld corrosion, cold bend restriction to the thermal
expansion, improper heat treatment and contouring of welds.

Failure of tube because of fly ash erosion is as shown in Fig: 9. As ash is having
abrasive action it erodes the outer surface of tube in Economizer, LTSH, Reheater
regions. Typical location of the fly ash erosions are, gaps between tubes, banks and
duct walls, gas by pass channels production of ferrous area close to large ash
accumulation the major causes of fly ash erosions are, Temperature of flue gas
,high ash content in coal high flue gas velocity and high impingement angle of ash
particle.
RESIDUAL LIFE ASSESSMENT
It is essential to identify the critical areas where failures are
likely to occur and select suitable NDE techniques for
detection of such failures.

DYE PENETRATION TEST

MAGNETIC PRACTICAL INSEPECTON [MPI]
IN-SITU OXIDE SCALE THICKNESS MEASUREMENT
DIMENSIONAL MEASUREMENT
FIBROSCOPIC INSPECTION
DYE PENETRATION TEST
This testing is carries out primarily to locate surface and sub-surface detects
such as cracks, pitting. As well pin holes, porosity and other flaws which occur
in almost any material.
This method involves application of liquid dye, which penetrates into the
surface flaw and highlighted as using a developer.
The developer absorbs the penetrate by capillary action there by highlighted
the flaw.

MAGNETIC PARTICLE INSEPECTON

Magnetic particle inspection (MP) is utilized to detect surface and near surface
flaws in ferrite material by including a magnetic field into the parent material.
By sprinkling wet fluorescent magnetic particles on the surface of the parent
material the magnetic fields are induced discontinues are located by observing
the patterns formed due to the distortions of the magnetic fields.
Magnetizing at least two mutually perpendicular fields ensures detection of
defects in all possible direction.
IN-SITU OXIDE SCALE THICKNESS MEASUREMENT

A portable oxide scale measurement machine is utilized to find

thickness of oxide layer of various critical components.

DIMENSIONALMEASUREMENT

Outside diameter measurements are generally employed to determine

the swelling due to creep. Diameter measurements are made using
digital venire calipers and bow gauges.

FIBROSCOPICINSPECTION

A flexible fibro scope is used for internal inspection of components

like headers, pipes, tubes etc. By illuminating and observing internal,
otherwise inaccessible. This inspection reveals the valuable information
about the inside condition of components.
Actions to be taken to prevent & control Boiler Tube
Failures

Keep all boiler and system fittings airtight

Add sodium chromate or sodium nitrite - nitrate inhibitors to the water in the quantities
recommended.
Preferably, use a fuel with low sulphur content to avoid the corrosive action of sulphur gases.
Use sodium sulfite regularly in the boiler feed water to remove dissolved oxygen.
100% radiography of weld its during overhaul & also during tube failure repair is to be carried out.
Use suitable feed water heater or deaerator to reduce the oxygen content of the boiler feed
water.
Prevent water leakage and avoid draining water from the system. Addition of make-up water
results in loss and dilution of the treatment, and introduces air into the system.
For determining the fire side corrosion and internal corrosion of furnace tubes, samples from each
corner of furnace must be sent to R & D in each unit overhaul.
suggestions

The primary consideration in material choice is a function of expected tube

temperature of operation.
Chromium and molybdenum additions to steel improve its resistance to cracking and
decarburization by forming carbides witch are more thermodynamically stable than
iron carbides. therefore carbon steel tubes used in boilers should be replaced by steel
containing Cr and Mo. Type of Cr-Mo steel will depend upon the condition of the
area where these tubes will be used
Overheating of the tubes should be avoided by effective cleaning of the steam side
surface of the tubes and removing all the tenacious deposits
If possible high quality coal want to use to reduce the erosion of boiler tube
During fabrication and assembly of the pipes with welded joints, care should be
taken to avoid generation of stress at the weld elements
Metal temperature limits
Analysis of boiler tube failures in solid work software

Chrome stainless steel

Carbon steel
Stainless steel
Alloy steel