Prediction of Remnant Life of Utility Boiler Tubes 1

Presented by:
Dr. P. R. Dhamangaonkar
Prediction of Remnant Life of Utility Boiler Tubes
Prediction of Remnant Life of Utility Boiler Tubes 2
Road Map of Presentation
1. Introduction
2. Failure Data nalysis
!. "cope of t#e pro$ect
%. &ear Rate '(uation and its )alidation
*. +onclusions
,. Prediction of Remnant Life of Tube
Prediction of Remnant Life of Utility Boiler Tubes 3
+ross "ection of 21- M& P+F Boiler
BOILER DRUM
WATER WALLS
WATER WALL PLATEN (WWP)
(PSH)
(CRH
& HRH)
(FSH)
(LTSH),
(ECO)
Prediction of Remnant Life of Utility Boiler Tubes 4
WI ND BOX
AI R+PF COAL
BOTTOM ASH
FL UE GASES
STEAM
WATER
PREHEATER
TO AI R FG
FG
FG
FG
P
L
A
T
E
N

W
W
ROOF
FROM HPT
TO I PT
TO HPT
DRUM
FURNACE
L
L
A
W
R
E
T
A
W
F
S
H
H
R
H
C
R
H
H
S
P
L TSH2
LTSH1
ECONOMI SER
Prediction of Remnant Life of Utility Boiler Tubes 5
1. Introduction

Fre(uent boiler tube failures in Utility Boilers

+ause .ise failure s#o.s more fre(uency of 'rosion

and /)er01eatin2 failure

'rosion and /)er01eatin2 failure often occurs in

'conomi3er4 Re0#eater and &ater .all 3ones

+onse(uences of tube failure

Prediction of Remnant Life of Utility Boiler Tubes 6
No Y!R "#T$%R!"L %!T & T#' (YN)$* %!T & T#'
+UT!,
$R(*
1 2--2.-3
1/*-3*-3
21*2- $rs
2-*-3*-3
23*15 $rs*
5-*-5
2 2--3.-4
-/*-4*-3
0*45 $s*
1-*-4*-3
23*15 $rs*
51*3
3 2--3.-4
3-*-4*-3
6*4- $rs*
-2*-5*-3
5*55 $rs
53*15
4 2--3.-4
1-*-1*-3
15*4- $rs*
12*-1*-3
0*3- $rs*
41*5
5 2--4.-5
-1*-4*-4
--*5- $rs*
-4*-4*-4
1-*5- $rs*
/2
6 2--4.-5
12*-4*-4
15*2- $rs*
15*-4*-4
-2*-5 $rs*
5/*45
1 2--4.-5
16*-5*-4
--*3- $rs*
1/*-5*-4
-1*-5 $rs*
4/*35
/ 2--4.-5
21*-6*-4
-3*-5 $rs*
23*-6*-4
--*3- $rs*
45*15
0 2--4.-5
16*-/*-4
13*-- $rs*
1/*-/*-4
1-*2- $rs*
45*2
1- 2--4.-5
-6*-0*-4
1/*15 $rs*
-/*-0*-4
16*2- $rs*
46*-5
11 2--4.-5
11*1-*-4
11*55 $rs*
10*1-*-4
10*-5 $rs*
40*55
12 2--4.-5
2-*-2*-5
21*1- $rs*
22*-2*-5
10*5- $rs*
46*4
13 2--5.-6
15*-5*2--5
22*25 $rs*
11*-5*2--5
1/*55 $rs*
44*3
14 2--5.-6
2/*1-*-5
-/*55
3-*1-*-5
1/*55 $rs*
5/
15 2--5.-6
1/*-1*-6
22*2- $rs*
2-*-1*-6
1/*1- $rs*
43*5
Average 61
BOILER TUBE LEAKAE REPORT OF UNIT ! "
Prediction of Remnant Life of Utility Boiler Tubes 1
Total +ost of Boiler Tube lea5a2e in a 6ear
Unit +apacity7 21- M&
)era2e /uta2e for one lea57 *1 #rs
8eneration loss and ot#er losses per 5&7 Rs. 2.,
+ost of one lea57 Rs. !42-42,4---90
+ost of appro:. 2- lea5s in a year7 Rs. 64,05,00,000/-
Prediction of Remnant Life of Utility Boiler Tubes /
;eed for Prediction of Tube Failure

Complex loat!ons

Remote loat!ons

"o!ler #$tage %osses

Present &ethods o' (a!l$re Detet!ons

Prediction of Remnant Life of Utility Boiler Tubes 0
)hat !s eros!on*
+n mater!al s!ene, eros!on !s the reess!on o' s$r'aes by
repeated loal!,ed mehan!al tra$ma as 'or example by
s$spended abras!-e part!le .!th!n a mo-!ng 'l$!d
#b/et!-es:
2
0o pred!t 'a!l$re
2
0o pred!t remnant l!'e
2
0o red$e %osses
Prediction of Remnant Life of Utility Boiler Tubes 1-
0he general!,ed -ar!ables r$l!ng .ear by eros!on are
1!2 0he relat!-e speed 3 o' part!le,
1!!2 0he mass & o' part!les,
1!!!2 0he hardness 4 o' .ear!ng mater!al,
1!-2 0he hardness 4a o' abras!-e mater!al,
1-2 0he angle o' attak 5,
1-!2 0he sharpness o' abras!-e mater!al,
1-!!2 0he o-e''!!ent '0 o' 'r!t!on o' eroded mater!al and
1-!!!2 Co-e''!!ent k6/,
)here, !s mater!al $tt!ng energy !n 7/ m8 and
!s energy neessary to remo-e a -ol$me $n!t o'
mater!al by de'ormat!on !n 7/ m8
Prediction of Remnant Life of Utility Boiler Tubes 11
0otal eros!on .ear 3 )total 6 ' 13, &, 4, 4a, 5,, '0, k2
n
E V

Part!le -elo!ty !s the most !mportant parameter

Prediction of Remnant Life of Utility Boiler Tubes 12
9
: 9 8
9
:
4 5 6 0 ;
, ,
, , ,
WH T Ha
V M T
f k

<pply!ng "$k!ngham-p! 0heorem,
9
0
9
:
9
9 a
0
:
)4
, , , , ,
3 &
0 4 &3
)6= , ,5,>,' ,k , ...........1:2
0 4 4
a
T H
f k
T H

_

,
_

,
0he express!on 'or .ear rate th$s an be g!-en as?
Prediction of Remnant Life of Utility Boiler Tubes 13
'rosion Mec#anism and 'rosion '(uation7
Bitter <1=*82 al$lated the total eros!on rate .h!h !s the s$m o'
eros!on d$e to $tt!ng and de'ormat!on mehan!sms, .!tho$t
!nl$d!ng the e''et o' temperat$re, by the 'ollo.!ng der!-ed
e@$at!ons.
total D C
W W W +
9
8
1 s!n 2
9
el
D
M V v
W m

&#ere4
( ) ( )
9 9
9 s!n s!n
os
s!n s!n
el el
C
MC V v C V v
W V
V V



_



,
For <>-?
Prediction of Remnant Life of Utility Boiler Tubes 14
Aomenlat$re
B Dens!ty o' part!le !mpat!ng !n Cg/m8
D Eo$ngFs mod$l$s o' elast!!ty o' eroded s$r'ae !n A/m9
D: Eo$ngFs mod$l$s o' elast!!ty o' erod!ng mater!al !n A/m9
D9 Eo$ngFs mod$l$s o' elast!!ty o' eroded s$r'ae !n A/m9
'0 Co-e''!!ent o' 'r!t!on 'or eroded mater!al, d!mens!onless
4 4ardness o' s$r'ae eroded !n A/m9
4a 4ardness o' abras!-e mater!al !n A/m9
k G/H
& 0otal mass o' Part!le !mpat!ng !n kg/m!n
m: %ethal abras!on o-e''!!ent, d!mens!onless
ms Ipe!'! mass o' part!le !mpat!ng !n kg/m8
@: Po!ssonFs rat!o 'or erod!ng mater!al, d!mens!onless
@9 Po!ssonFs rat!on 'or eroded mater!al, d!mens!onless
R Rad!$s o' sphere !mpat!ng 1part!le2 !n mm
re Rad!$s o' pro/et!on o' ontat area o' a sphere .!th a body .hen
elast! l!m!t !s /$st reahed !n mm
rp Rad!$s o' pro/et!on o' that part o' the ontat area s$b/eted to
plast! elast! load !n mm
rt Rad!$s o' pro/et!on o' ontat area !n a plast! elast! !mpat !n mm
Prediction of Remnant Life of Utility Boiler Tubes 15
3 3elo!ty o' part!le !mpat!ng !n m/s
vel %!m!t!ng speed o' 'a!l$re 'or .h!h the mater!al st!ll has elast! beha-!or
!n m/s
vr Res!d$al tangent!al speed o' part!le a'ter !mpat!ng !n m/s
)c Dros!on .ear d$e to $tt!ng !n mm8/m!n
)D Dros!on .ear d$e to de'ormat!on !n mm8/m!n
)total 0otal eros!on .ear !n mm8/m!n
y Dlast! load l!m!t !n A/m9
Greek Letters
Dnergy neessary to remo-e a -ol$me $n!t o' mater!al by de'ormat!on !n
7/ mm8
5 <ngle o' attak o' part!le !n degree
J "o$ne angle o' part!le !n degree
K: 0arget mater!al temperat$re !n 0C
K9 Part!le temperat$re !n 0C
> Iharpness 'ator 'or abras!-e mater!al, d!mens!onless
L Po!ssonFs rat!o, d!mens!onless
,G &ater!al $tt!ng energy 'ator !n 7/ mm8
Prediction of Remnant Life of Utility Boiler Tubes 16
0h$s the ded$ed .ear rate e@$at!on !s
9
9 9
os s!n s!n
9
total
MV
W k

+
1
]
)here,
& total mass o' !mpat!ng part!les !n kg/se
3 -elo!ty o' !mpat!ng part!le m/se
5 !mpat angle o' the part!le !mp!ng!ng on the s$r'ae !n rad!an
G !s mater!al $tt!ng energy 7/m8 and
H mater!al de'ormat!on energy 7/m8
J bo$ne angle o' part!le and
!t depends $pon o-e''!!ent o' 'r!t!on '0 and
k

Aeed o' 3al!dat!on

Prediction of Remnant Life of Utility Boiler Tubes 11
@alidation of t#e De)eloped &ear Rate e(uation7
9
9 9
os s!n s!n
9
total
MV
W k

+
1
]
< general!sed .ear rate e@$at!on
0est .ere ond$ted at Central Po.er Researh +nst!t$te, "angalore.
Deta!ls o' 0est:
!2 0est Ipe!men:
Iample : DA 8:, 8 samples 'or one
angle.
Iample 9 &.I, 8 samples 'or one angle.
!!2 Ipe!men s!,e:
Iample : DA 8:, ;5 x 96.5 x ;
mm
Iample 9 &.I, ;5 x 95 x ; mm
G6 mater!al $tt!ng
energy 'ator !n 7/mm8
46 bo$ne angle o'
prat!al
Prediction of Remnant Life of Utility Boiler Tubes 1/
!!!2 4ardness -al$es:
4ardness o' sample :6 9M; 43
4ardness o' sample 9 699; 43
4ard ness o' s!l!a part!les :000-::00 43 1<ss$med2
!-2 0est Cond!t!ons:
<!r press$re 6 0.65 bars
Part!le mesh 6 855 &!rons
Ao,,le d!ameter6 5.9 to 4.M mm
Itand o'' d!stane 6:0 mm
&ass 'lo. rate o' abras!-e 6 600 to ;00 gm/m!n
Part!le -elo!ty at the ex!t o' no,,le 688 N 9 m/s
<bras!-e part!les I!#9 1s!l!a sand2
+mpat angles 5 6 :5, 80, 45 O P0 degrees.
0est d$rat!on 80 seonds.
-2 Dros!on rate !s meas$red by .e!ght meas$rement be'ore and a'ter test.
Prediction of Remnant Life of Utility Boiler Tubes 10
T#e test results for sample 1
Impact an2le in
de2rees
"pecimen
;/.
&ei2#t
before test4
In 2rams
&ei2#t
after test
In 2rams
'rosion
.ei2#t
loss4
In 2rams
)era2e
'rosion
In 2rams
A B 1,-
1 112.%!*C 112.%2%D -.-121
-.-12D 2 1-=.1=2* 1-=.1D=% -.-1!2
! 1-C.12*% 1-C.11!* -.-12C
A B!--
1 112.%2%D 112.%-*! -.-1C%
-.-1=, 2 1-=.1D=% 1-=.1,=1 -.-2-!
! 1-C.1-=1 1-C.-C=2 -.-1==
A B%,-
1 112.%-%C 112.!CD% -.-1D%
-.-1D, 2 1-=.1,*D 1-=.1!C= -.-1DC
! 1-C.-C*= 1-C.-*=* -.-1D!
A B=--
1 112.!C*% 112.!D,* -.-1-C
-.-1-1 2 1-=.1!C= 1-=.12=, -.--=%
! 1-C.-*=* 1-C.-,=! -.-1-!
Prediction of Remnant Life of Utility Boiler Tubes 2-
T#e test results for sample 2
Impact
an2le in
de2rees
"pecimen
;/.
&ei2#t
before test
In 2rams
&ei2#t after
test
In 2rams
'rosion
.ei2#t loss
In 2rams
)era2e
'rosion
In 2rams
1 1-2.=C%C 1-2.=**! -.-1%1
A B 1,- 2 1-!.%D2% 1-!.%,C, -.-1!D -.-1!,
! 1-!.%2D, 1-!.%1%C -.-12D
1 1-2.=**! 1-2.=%!, -.-22C
A B !-- 2 1-!.%,C, 1-!.%!%C -.-2!D -.-22C
! 1-!.%1%C 1-!.!=2= -.-21=
1 1-2.=21C 1-2.=-1- -.-2-C
A B %,- 2 1-!.%!%1 1-!.%1-D -.-2!% -.-221
! 1-!.!=11 1-!.!*CD -.-22%
1 1-2.=-1- 1-2.C=-D -.-1-!
A B =-- 2 1-!.%1-D 1-!.!==C -.-1-= -.-11-
! 1-!.!D2C 1-!.!*-= -.-11=
Prediction of Remnant Life of Utility Boiler Tubes 21
G and H 'or Iample : O 9
Iample G H
: 4;.9: 7/mm8 :9; 7/mm8
9 45.0P 7/mm8 ::6.6; 7/mm8
0he general!sed .ear rate e@$at!on 'or Iample : and Iample 9

(or Iample :
9
9 9
os s!n 9 0.8;s!n
9 4;.9:
total
MV
W +

1
]
9
9 9
os s!n 9 0.8Ms!n
9 45.0P
total
MV
W +

1
]

(or Iample 9
Prediction of Remnant Life of Utility Boiler Tubes 22
Compar!son o' 0heoret!al and Dxper!mental )ear Rate
Iample <ngle !n,
degree
Cal$lated
-al$e
grams/80 se
&eas$red
-al$e
grams/ 80 se
I<& :
:5 0.0:84 0.0:9;
80 0.09:P 0.0:P5
45 0.0:M; 0.0:;5
P0 0.0:0: 0.0:0:
I<& 9
:5 0.0:60 0.0:85
80 0.096: 0.099M
45 0.0:P6 0.099:
P0 0.0::0 0.0::0
&ax!m$m )ear may take plae at 5 880
Prediction of Remnant Life of Utility Boiler Tubes 23
%et $s pred!t the 'a!l$re o' a spe!men.
&ater!al I< 9:0 QR <: .!th tens!le strength aro$nd 4:4 &Pa.
+nternal press$re o' :40 to :50 bars
9 0.M
cr
y
pd
The critical thickness t

3ol$me o'
eroded
mater!al
0!me re@$!red to remo-e mater!al
m!n
AL
W

Prediction of Remnant Life of Utility Boiler Tubes 24

@alue of impact an2le for ma:imum erosion
Cons!der the general!,ed eros!on rate e@$at!on,
9
9 9
os s!n s!n
9
MV
W k

+
1
]
Ao., d!''erent!at!ng th!s e@$at!on .!th respet to 5,
+n ase o' arbon steel max!m$m eros!on takes
plae .hen 56880
Prediction of Remnant Life of Utility Boiler Tubes 25
Compar!son bet.een the res$lts obta!ned 'rom
exper!mentat!on and al$lated -al$es 'rom the
de-eloped eros!on rate e@$at!on.
"ample 1
n2le4
de2rees
+alculated )alue
2rams9!- sec
Measured )alue
2rams9 !- sec
1, -.-1!% -.-12D
!- -.-21= -.-1=,
%, -.-1CD -.-1D,
=- -.-1-1 -.-1-1
Prediction of Remnant Life of Utility Boiler Tubes 26
Compar!son bet.een the res$lts obta!ned 'rom
exper!mentat!on and al$lated -al$es 'rom the
de-eloped eros!on rate e@$at!on.
"ample 2
n2le4
de2rees
+alculated )alue
2rams9!- sec
Measured )alue
2rams9 !- sec
1, -.-1*- -.-1!,
!- -.-2*1 -.-22C
%, -.-1=* -.-221
=- -.-11- -.-11-
Prediction of Remnant Life of Utility Boiler Tubes 21

0he eros!on rate e@$at!on .!ll g!-e amo$nt o' mater!al

eroded !n part!$lar t!me per!od

+' .e kno. the @$ant!ty o' mater!al to be remo-ed to 'a!l

the t$be then .e may al$late the t!me at .h!h the t$be
may 'a!l.

%etFs '!rst start .!th '!nd!ng o$t the r!t!al th!kness o'
bo!ler t$be at .h!h !t may 'a!l.
LIF' PR'DI+TI/; /F TUB'"
Prediction of Remnant Life of Utility Boiler Tubes 2/
0h!s e@$at!on .!ll g!-e the -ol$me o' mater!al eroded !n : m!n$te.
Io, !' .e kno. the -al$e o' !mpat!ng part!le -elo!ty, mass 'lo.
rate o' part!les !mpat!ng, !mpat angle o' part!les and the type o'
mater!al then .e an '!nd o$t the -ol$me o' mater!al eroded !n one
m!n$te.
9
9 9
os s!n s!n
9
total
MV
W k

+
1
]
0h$s the t!me !n .h!h the t$be may 'a!l,
0!me m!n
AL
W

Prediction of Remnant Life of Utility Boiler Tubes 20

Prediction of failure time of tube if it is sub$ected to actual
flo. conditions

%et $s ass$me that the t$be !s made $p o' sample :

0he d!mens!ons o' the t$be are 44.5 x 4.5 mm

0he a-erage -elo!ty o' part!les !mpat!ng !s 9.5 m/s

Part!les are 'ly ash part!les .!th hardness aro$nd 500 43

4ardness o' sample : 9M; 43

0he !nternal press$re !s aro$nd :50 bars

E!eld stress 955 &Pa

<-erage !mpat angle !s 800 at .h!h max. eros!on o$rs

0he mass 'lo. rate o' 'l$e gas !s P:0 tones / ho$r. 0hat means
958 kg/se 'rom area o' ::8.:6 m9 that means 9.98
kg/se.m9
Puttin2 t#is )alues in abo)e e(uations 4
Prediction of Remnant Life of Utility Boiler Tubes 3-
%et $s take a ase .hen ond!t!ons are nearer to at$al ond!t!ons.
+mpat!ng Part!les: (ly ash part!les.
<ord!ng to the data obta!ned 'rom Aash!k 0hermal Po.er Itat!on,
0$be +D 6 44.5 mm O 0h!kness 6 4.5 mm.
<-erage -elo!ty o' !mpat!ng part!les 6 9.5 m/s.
4ardness o' !mpat!ng part!les 6 500 43 1aprox.2.
4ardness o' t$be sample : 6 9M6 43
<t!ng Press$re 6 :50 bars
0he mass 'lo. rate o' 'l$e gas !s P:0 tones / ho$r
0he r!t!al th!kness 6 tr 6 :.65 mm. O <rea6 <6 5: mm9
Time B *,1% mins B 11*-C #ours B %C! days B 1.!2 years
Prediction of Remnant Life of Utility Boiler Tubes 31
+n that ase the total .ear e@$at!on,
9
9 9
os s!n 9 0.8;s!n
9 4;.9:
H
a
f
total
H
MV
W
_

,
+

1
]
P$tt!ng all the -al$es o' parameters .e get,
Wtotal= ;.89 x :0-4 mm8/m!n
Io the t!me !n .h!h the t$be may 'a!l 6 ALW m!n$te
6 6P65:4 m!ns 6:.89 years
Prediction of Remnant Life of Utility Boiler Tubes 32
0hat means !' the t$be 144.5R4.52 made o' sample : !s
s$b/eted to ont!n$o$s eros!on by abras!-e part!les o'
s!l!a sand .!th -elo!ty o' 88 m/s and mass 'lo. rate 0.6
kg/m!n and !mpat angle 800 .!th !nternal press$re o'
:59 bars and 'orm!ng a rater o' :0 mm, and then !t may
'a!l !n :.89 ho$rs.
Pred!t!on o' Remnant %!'e
Prediction of Remnant Life of Utility Boiler Tubes 33
+omparison bet.een t#e results obtained from e:perimentation
and calculated )alues from t#e de)eloped erosion rate e(uation.
Iample
Ao.
%oat!on <t$al
Dros!on
!n Qrams
<t$al
Dros!on
!n kg/m!n
<-erage
Dros!on
Cg/m!n
Dst!mated
Dros!on
!n kg/m!n
3ar!at!on
:2 0-: (- %4I PP.00 9.6 x :0-;
9.8;x :0-; :.5M; x:0-; 88 S
92 0- 8 R- %4I ;5.00 :.P x :0-;
82 0-96M (- R4I 84.00 M.6 x :0-M
42 0-9;0 R- R4I :0:.00 9.6 x :0-;
0he ded$ed .ear rate e@$at!on an be $sed 'or remnant l!'e
analys!s and pred!t!on o' t$be 'a!l$re !' the -elo!ty o' 'l$e gases !n
the bo!ler and press$re part reg!on !s kno.n/pred!ted.
Prediction of Remnant Life of Utility Boiler Tubes 34
($t$re .ork $ndertaken

Pred!t!on o' (l$e gas -elo!ty o-er the ent!re press$re

part ,ones o' 9:0 &) PC( "o!ler.

Pred!t!on o' (l$e gas 0emperat$re o-er the ent!re

press$re part ,ones o' 9:0 &) PC( "o!ler

Pred!t!on o' e''et o' '$el @$al!ty on (l$e gas -elo!ty

and 0emperat$re o-er the ent!re press$re part ,ones o'
9:0 &) PC( "o!ler
Prediction of Remnant Life of Utility Boiler Tubes 35
0he a$thors had tr!ed to ded$e eros!on rate e@$at!on $s!ng e@$at!on
de-eloped by <. &agnee. 0he ded$ed eros!on rate e@$at!on onta!n
only mass, !mpat angle and -elo!ty as -ar!ables go-ern!ng eros!on.
0h!s .ear rate e@$at!on an be $sed to pred!t the .ear. 0he
e@$at!on an also be $sed 'or remnant l!'e analys!s. < ase st$dy !s
done on one o' the ommonly $sed po.er plant mater!al 1I<
9:0/QR <:2. 0h!s e@$at!on !s -al!dated .!th exper!mentat!on at
CPR+ "angalore. 0he a$thors are also st$dy!ng the e''et o' d!''erent
parameters part!$larly s$r'ae temperat$re and hardness o' mater!al
on eros!on and get '$nt!onal relat!onsh!p bet.een eros!on .ear and
-ar!o$s 'ators.
+onclusions7
Prediction of Remnant Life of Utility Boiler Tubes 36
Thank You
Prediction of Remnant Life of Utility Boiler Tubes 31
(tatus of Pul5eri6ed )oal 7ired Boiler tube failure in a NTP( #ndia
History of zone-wise boiler tube failures in 210 MW units at plant under study
Prediction of Remnant Life of Utility Boiler Tubes 3/
"R .
;/
6'R
+U"'"
2
-
-
%
0
-
,
2
-
-
,
0
-
*
2
-
-
*
0
-
D
2
-
-
D
0
-
C
2
-
-
C
0
-
=
2
-
-
=
0
1
-
T
/
T

L
1 'rosion 1! 12 1- 22 11 , D!
2 "tress +orrosion 2 % 1 - - - D
! .ater +orrosion - 1 2 - - - !
% Diss. Et Failure % 1 - 1 1 - D
, /)er 1eatin2 D 1, 12 1D ! , ,=
* 1P Et. Failure D ! 2 , ! 1 21
D +#emical +leanin2 - - - - - - -
C Freetin2 2 1 2 - - 1 *
= ir in2ress - 1 2 - 1 - %
N# #$ Fa%&'re %( )ear* Ca'*e #$ Fa%&'re N#
Boiler Tube Lea5a2es7 +ause &ise
Prediction of Remnant Life of Utility Boiler Tubes 30
8eometric Modelin2 of 21- M& Boiler

2D )ie. of t#e boiler model
WATER WALL PLATEN (WWP)
(PSH)
(CRH
& HRH)
(FSH)
(LTSH),
(ECO)
Prediction of Remnant Life of Utility Boiler Tubes 4-
8eometric Modelin2 of 21- M& Boiler

Prediction of Remnant Life of Utility Boiler Tubes 41
Boiler 8eometry .it# Porous bloc5s for pressure parts .it# e(ui)alent inertia resistance
Prediction of Remnant Life of Utility Boiler Tubes 42
Mes#ed porous components and flue 2as space.
Prediction of Remnant Life of Utility Boiler Tubes 43
Res$lts and D!s$ss!ons
@elocity )ectors4 Ref. Plane0 D.*- m from left .all
Prediction of Remnant Life of Utility Boiler Tubes 44
Res$lts and D!s$ss!ons
@elocity )ectors4 Ref. Plane0 -.1 m from left .all
Prediction of Remnant Life of Utility Boiler Tubes 45
Res$lts and D!s$ss!ons
@elocity )ectors4 Ref. Plane0 1!.CD m from left .all
Prediction of Remnant Life of Utility Boiler Tubes 46
Res$lts and D!s$ss!ons
@elocity )ectors4 Ref. Plane0 D.*- m from left .all
@elocity )ectors4 Ref. Plane0 -.1 m from left .all @elocity )ectors4 Ref. Plane0 1!.CD m from left .all
Prediction of Remnant Life of Utility Boiler Tubes 41
Temperature Distribution
Prediction of Remnant Life of Utility Boiler Tubes 4/
Prediction of Flue 8as @elocity and Temperature< 6F planes?
Prediction of Remnant Life of Utility Boiler Tubes 40
Prediction of Flue 8as @elocity and Temperature <G0F Planes?
Prediction of Remnant Life of Utility Boiler Tubes 5-
Prediction of Flue 8as @elocity and Temperature <alon2 6G Planes
Prediction of Remnant Life of Utility Boiler Tubes 51
"o!ler 0$be
(l$!d
Iale
R!se !n I$r'ae 0emp.
Iteam "lanket!ng
+reep Mec#anism
Prediction of Remnant Life of Utility Boiler Tubes 52
+omparison of /nsite ':perimental Results .it# &ear rate
'(uation.
Iar!'!!ng spe!mens .ere kept !n the eonom!,er ,one !n 9:0
&) bo!ler and exposed to 'l$e gas .!th ash part!les. 0he
spe!mens .ere p$t d$r!ng one sh$t do.n and remo-ed d$r!ng next
sh$t do.n. 0he test spe!mens then .ere heked 'or eros!on.
Date o' Iamples !nstalled: :8/0;/900P
Date o' Iynhron!,at!on: :4/0;/900P
Date o' Remo-al o' samples: 95/08/90:0
D$rat!on o' 0est: 9;4 days 6 8,P4,560 m!n
A$mber o' Iamples: 4
Ipe!men &ater!al: I< 9:0 Qr :
)e!ght o' Ipe!men be'ore !nstallat!on: 68; gms