Residual Life Assessment and Life Extension Programme in Utility Boilers BHELs Experience

Dr V T Sathyanathan, M.E., Ph.D. Additional General Manager / Research & Development BHEL, Tiruchirappalli 620014 1.0 INTRODUCTION Thermal power plants form the major portion of the installed capacity in our country and , there always exist a wide gap between supply and demand of energy. To bridge this gap , there is a need to set up new plants for which huge financial investments and long gestation period is required . Indias thermal Power generation started in 1899 with small thermal power plant with stoker fired Boilers. We have then moved on to 30 MW, 60 MW, 110 MW, 200/210 MW and 500 MW unit rating in the last 2 to 3 decades. Indias power requirement is increasing at an exponential rate and is installed generation capacity will be gestation expected that more than 1,50,000 MW of thousand corers.

required by 2000 AD. This may need very high initial investment to the tune of a few Combined with this huge financial requirement, the period for new units are still in the range of 24 to 36 months depending upon the rating of the units. Hence, there is a need to look at our ageing units and get their useful life extended. In India about 15 20 % of utility power generation can be taken as power from captive power generation. Hence to meet the immediate power demand, the attention is focussed on extending the useful life of ageing power plants . Rehabilitation of ageing steam generators through life extension program is the most cost effective method to achieve the extended useful life . The concept of Renovation and modernisation through life extension program has picked up momentum in India and all over the world ,as it provides the cost effective solution to meet the increased power demand. Life extension program involves thermal performance study ,Residual life assessment study , life extension , capacity regain and efficient operation through modernisation . In India ,majority of the units have either crossed or nearing their design life, and there is a need to ensure reliable output from these units for an extended period which
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will help in minimising the gap between supply and demand to some extent. Remaining life assessment of these units will help in identifying the critical areas that need refurbishment / replacement , which when carried out will ensure reliable operation. Boilers normally designed for a specific life are capable to deliver an extended useful life because of the conservatism built-in during design stage itself. Pressure part components operating at high pressure and temperature are prone for service damages like creep, fatigue or a combination of creep and fatigue. The assessment calls for certain special techniques over and above the routine requirements like laboratory analysis by doing destructive testing through sampling and Non- destructive examination like Ultrasonics , Oxide scale thickness measurement etc., . Special techniques as detection of hydrogen damage in waterwalls by attenuation method as well as corrosion damage of pressure part components are employed on a need based requirement, depending upon the operational history of specific unit. Assessment programme will help in identifying the components that can be considered for continued operation , components that need reexamination after specific interval and components that require modification/replacement so that the utility can plan life extension activity in a programmed and phased manner. This enables the owner to stagger the investment necessary for such rehabilitation in costeconomic way. Units that have limitation in achieving full load can be specifically addressed in the rehabilitation programme so as to regain the lost capacity. Certain state-of-the art improvements in design could also be investigated for implementation to improve the efficiency of the plant. BHEL, as a premier Organisation in the Power Sector of India, through our rich experience over 30 years and also through extensive research carried out over a period of more than 15 years in the field of Life assessment and extension of Power plant equipment has emerged as one of very few organisations in the world capable of offering and executing comprehensive packages of total Thermal Power plants. successfully. R & M and upgradation of the BHEL/Tiruchi, the High pressure Boiler Plant has

upgraded number of such Power stations in India and Abroad in the past 15 years

Dr V T Sathyanathan, M.E, Ph.D. BHEL, Trichy 62014

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2.0 RESIDUAL LIFE ASSESSMENT STUDY As we go into the details of pressure part life assessment, it is worth looking into material damage mechanisms, which can cause pressure part failures and reduction in life of the pressure parts. Pressure parts deteriorate continuously during service due to time dependent degradation mechanisms such as oxidation, corrosion, creep, fatigue and interactions of the above. In actual practice, material damage results from interactions of two or more of these failure causing mechanisms.

Long term overheating

Thermal Fatigue

Hydrogen Embrittlement

Low temperature corrosion

Components may fail prematurely due to unforeseen system stresses and stress concentrations, operation under conditions not originally envisaged at design stage like cycling, excessive temperature, corrosion and erosive environments. Local conditions and operational factors associated with a particular unit dictate the type and

Dr V T Sathyanathan, M.E, Ph.D. BHEL, Trichy 62014

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extent of damage to a component. Hence, independent study of each unit even in the same station is a basic need to establish the precise status of each component. Various methods of measuring creep life assessment may be classified into two categories. Method based on the operational history is examined on the in which the expended life of a component basis of operational history and standard

material properties. Methods based on post service examination and / or testing on the actual component. Precise operational data seldom available in practice. Moreover, as the lower bound stress rupture properties are considered in the absence of precise knowledge of the material data, operational history based approach leads to pessimistic life assessment. However, such an exercise would be very useful in identifying the critical component that require thorough scrutiny. Post exposure test (PET) comprises of destructive and non-destructive techniques. These methods require accessibility to the actual component and hence can be taken up only during overhauls or planned outages. Destructive test approaches are helpful in arriving at numerical estimates of remaining useful life. In case of boiler components like superheater tubes destructive testing by sampling can also be used since it is relatively easier to remove the samples and reweld with spool pieces, as compared to the headers and steam pipes of boiler. In case of thick walled components, it is advisable to combine all the NDT approaches along with replication to study the surface metallography. The various steps adopted in pressure part life assessment in involve the following: * Review of operational history of equipment. * Analysis of data records and maintenance/overhaul reports * Analysis of failure records and reports. * Visual examination. * Non-destructive examination. * Tube Sampling for laboratory analysis and hot burst testing. * Sampling of deposits for laboratory analysis . In-situ metallography replica technique.

Dr V T Sathyanathan, M.E, Ph.D. BHEL, Trichy 62014

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2.1 Review of Operational History of equipment : The operational history of the equipments/boiler is reviewed with reference to number and details of startup and shutdown, operational regimes maintained, duration and extent of parameter escalation especially steam temperature and water chemistry regimes. This information helps in identifying the extent of deviation in operating condition from design and consequently the areas to be examined in detail by destructive/non-destructive methods can be identified . 2.2 Analysis of Data Records and Maintenance / Overhaul Reports : Observations during planned shutdown provide a wealth of information on equipment condition / deterioration. Generally this information is utilized by the maintenance planning division for preventive maintenance and replacement. History cards covering replacements done during routine maintenance/forced outages and planned overhauls will be reviewed so that current status of the unit is assessed and equipment degradation trend formulated. Analysis of the data along with design review helps in formulating the maintenance strategy and also in deciding scope of detailed examination. 2.3 Analysis of Failure Records and Reports : As the main aim of the life assessment study is to ascertain/ extend the life of components designed with a finite life, the failure records are a basic source of information for the study. Reports containing detailed metallurgical analysis will help in evaluating the failures. Marking up of pressure part failures in the arrangement drawing helps in identifying the weaker areas. Analysis reports on premature failures can indicate the deviations in operating conditions or design lacunas that need correction for extending the life of the components. 2.4 Visual Examination : Visual examination is carried out to assess material wastage due to oxidation, erosion/ corrosion problems, fouling conditions of heat transfer surfaces, integrity of attachments in coils and hanger supports in piping. This includes inspection of drum inside surface for corrosion, presence of magnetite coating and soundness of drum internals to ensure proper steam/water separation. During visual inspection the observations made with reference to decoloration of coils, misalignment are considered in deciding sample tubes removal for metallurgical examination. Prior evaluation of pressure part condition, based on experience and design knowledge from similar plants make sample selection more rational. Samples from the regions thus determined to be most susceptible to failures and samples depicting the general condition of each component, are selected for an evaluation of the metallurgical condition.
Dr V T Sathyanathan, M.E, Ph.D. BHEL, Trichy 62014

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2.5 Dimensional Measurements : Essentially thickness and outside diameter measurements form the dimensional measurements. Thickness measurements at critical areas give a measure of thickness loss over the year due to erosion and corrosion. Outside diameter measurements are generally employed to determine the swelling (bulging) due to creep. 2.6 Non-Destructive Examination : The following Non Destructive Examination ( NDE ) are normally carried out prior to examination by replica technique. 2.6.1 Liquid Penetrant Examination : This technique is adopted primarily for detection of cracks or crack like discontinuities that are open to the surface of a part, like surface porosity, pitting, pin holes and other weld defects. In principle, the liquid penetrant is applied to the surface to be examined and allowed to enter into the discontinuities. All excess penetrant is then removed, surface dried and the developer applied. The developer serves both as a blotter to absorb the penetrant coming out by capillary action and as a contrasting background to enhance the visibility of the indication. 2.6.2 Magnetic Particle Examination : This technique is adopted for locating surface and sub-surface discontinuities like seams, laps, quenching and grinding cracks and surface rupture occurring on welds. This method is also used for detecting surface fatigue cracks developed during service. Magnetic particle inspection helps to detect cracks and discontinuities on or near the surface in ferromagnetic materials using dry magnetic particle testing equipment. The testing is done by magnetising at least two mutually perpendicular direction to ensure detection of defects in all possible orientations. 2.6.3 Ultra-sonic Testing : By using high frequency sound waves the surface and sub surface flaws can be detected. Cracks, laminations, shrinkages, cavities, flakes, pores and binding faults that act as discontinuities in metal gas interfaces can also be easily detected 2.7 Sampling for Laboratory Analysis and Creep Rupture Testing : Tube samples carefully selected after the visual inspection are analysed in laboratory for material degradation, extent of oxide scaling and corrosion /erosion. Tube deposit analysis, internal and external surface condition assessments aid in identifying the root cause of failures/degradation. Tube samples are taken from water walls in all the four walls at the high heat flux region, SH, RH and Eco (if required based on past failure data).

Dr V T Sathyanathan, M.E, Ph.D. BHEL, Trichy 62014

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2.7.1 Waterwalls : Waterwall tube samples will be removed from high heat flux zone for evaluating the deposit content and constituents of the deposits. Weight loss method is adopted for calculating deposit content. The need for chemical cleaning will be decided based on the deposit content and the constituents of the deposit. The analysis report may include the need or otherwise for chemical cleaning. Recommendation on solvent for ensuring the effective removal of the deposit will also be included as per requirement. 2.7.2 Metallurgical Examination of High Temperature Tubes : The tube samples removed from superheater will be analysed for any metallurgical degradation in service. Transverse ring segments from the tubes will be metallographically prepared and examined using light optical microscope up to a magnification of 500 x. Carbide morphology and distribution, presence of creep cavities, dimensional evidence of creep bulging, and tube wall thinning will be evaluated. The oxide scale thickness on steam side surface will be measured and used in estimating the extent of damage as also the general operating temperature for the running hours. 2.8 In-situ Metallography by Replica Technique : The high temperature components in utilities when subjected to high stress for a long time undergo steady changes in transformation of strengthening carbide phases followed by creep cavitation. This is the beginning of creep or slow plastic deformation leading to gradual bulging of pressure parts

Figure 1 : Preparation of surface for replication

Dr V T Sathyanathan, M.E, Ph.D. BHEL, Trichy 62014

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The following three distinct stages of creep occur in several alloys. The first stage of creep occurs in a short period which is transient. The second stage or steady state creep occurs over a very long duration of several years. The metallurgical changes like carbide transformation and dispersion occurs. In this stage formation of minute creep voids along the grain boundary surfaces also accompanies creep deformation. In the third stage of creep, the creep voids increase in number and size and get oriented and connected. They generate micro cracks, and the micro cracks connect themselves resulting in the initiation and growth of macro crack with sudden fracture in some zones depending on the operating stress at that zone. The replication is the technique adopted to obtain the microstructure 'in-situ' by nondestructive metallography. This technique is used in areas where sample removal is difficult and not viable on cost economic aspects. Figure 2 shows a pictorial representation of taking replica.

. Figure 2 A pictorial representation of taking replica As far as the thick walled components like headers and main steam line and hot reheat lines are concerned, the replica taken are evaluated based on Wedel and Neubauer classification. 2.9 Remnant Life Determination based on Accelerated Creep Rupture Testing Superheater tubes operating at higher temperatures (more than 450C)are subjected to a time dependent phenomena known as creep. The sample tubes removed from boiler will be subjected to creep rupture tests at accelerated temperature and at service pressure in the test facility available at laboratory. The test parameters can be controlled within close limits. To predict remaining life from the results following method is adopted. A. Parametric extrapolation B. Application of life fraction rule. of rupture tests, the

Dr V T Sathyanathan, M.E, Ph.D. BHEL, Trichy 62014

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2.9.1 Parametric extrapolation : Specimen from each sample tube will be subjected to a specified stress and temperature. Time to rupture versus temperature will be plotted and the extrapolation will be done for the operating temperature to decide the remaining life. The assumptions made in the above method are a) Thickness variation is not considered and hence the operating stress is assumed as uniform. b) Metal temperature considered for extrapolation is assumed as constant and metal temperature increase due to building of oxide scale over a period is not accounted. 2.9.2 Application Of Life Fraction Technique : The life fraction rule says that during creep the fractional reduction in life after time t , at a given stress and temperature is t / tr , where tr is the time to rupture under the same stress and temperature. The failure would occur when sum of the fractions of life equals unity. 2.10 Remnant Life Calculation based on Service Temperature : Tube samples removed from boiler are evaluated for microstructure classification based on which the service temperature can be evaluated taking into consideration the operating hours collected from the plant records. Another method of estimating operating temperature is based on oxide scale measurement. As steam passes through the tubes at high temperature, the metal is oxidized. Knowing the operating hours and oxide thickness measured in mils, the average temperature 't' is calculated . 2.10.1 Calculation of Remaining Life : Assuming oxidation rates for a specific period , the average stress can be calculated for the aging duration considered. With average stress value LarsenMiller parameter can be calculated for the particular material. With the LarsenMiller parameter rupture life can be calculated using metal temperature values. Fraction of life consumed is the ratio of operating period divided by rupture life. The accumulated damage is the sum of fractions. 3.0 BHEL S EXPERIENCE BHEL has undertaken remaining life assessment studies of industrial as well utility boilers covering more than 120 units. The details of the boilers where RLA is carried out by BHEL (as on July 2000) is groped in to Power boilers, Industrial boilers, BHEL, Non-BHEl boilers, in India and abroad and is given below.

Dr V T Sathyanathan, M.E, Ph.D. BHEL, Trichy 62014

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Total Number Of Boilers (As on July 2000) Power Boilers Industrial Boilers BHEL Boilers In India In Abroad Non BHEL Boilers In India In Abroad

127 71 56 52 42 10 75 75 -

The details of assessment and recommendations pertaining to specific three units are discussed as case studies. The first case study refers to a boiler supplied to a refinery which was taken up for study when the unit had clocked about 150,000 hrs. of operation. The findings from the study revealed that except for replacement of outlet header of SH the remaining components were found to be good for continued operation. The second case study is relating to a reheat balanced draft unit which was taken up for study after 130,000 hrs of operation. This unit had experienced frequent outages on account of reheat system. The methodology and the scope was finalised based on operational history. The findings from the study revealed that most of the components were found to be good for continued operation and the anticipated life can be achieved only with for part replacement of hot reheat header and reheater coils. The third case study is relating to a reheat, balanced draft unit which was taken up for assessment when the unit has clocked 110,000 hrs. This unit had forced outages in platen superheater and in economiser, because of which the utility had done replacement of the above prior to study. Since this boiler had certain limitations in achieving the rated capacity and also there was a need to improve the boiler efficiency, the rehabilitation proposal called for measures to take care of the above aspects over and above the scope identified from the findings of remaining life assessment study. 3.1 CASE STUDY I 3.1.1 Boiler Details : Evaporation capacity Design pressure Design Temperature Type Material used Service Hours : 75 TONS/HR : 39 KG/ SQ. CM : 440 C : Non reheat / Balanced draft ( Russian Design ) : Steel 20 ( Equivalent to Carbon Steel ) : 150, 000

Dr V T Sathyanathan, M.E, Ph.D. BHEL, Trichy 62014

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3.1.2 Field Study : The non reheat boiler operating at temperature below 427 C was checked mainly for integrity of welds and also for suitability of waterwalls and superheater coils for continued operation. Though the components are designed for an operating temperature below 427 C, replication was carried out at SH outlet header considering the service hours to which the components have been subjected. The study revealed that the condition of boiler drum , water walls and SH coils are good enough for continued operation. The secondary superheater outlet header when examined with fiberscope indicated presence of ligament cracks in longitudinal section . Few ligaments on the left extreme were only found to have cracks where as the other ligaments were found to be having just initiation of cracks. To bring back the unit in service, it was necessary to replace the header as the crack size in few ligament locations were beyond acceptable limits. As the unit was not having readily a spare header for replacement, it was decided to partly remove the left extreme portion of the header which had cracks in ligaments beyond acceptable level and start the unit. The superheater coils pertaining to the removed portion were retained in position in order to avoid any possible gas laning. The removed portion of header material was analysed in Laboratory and the lab analysis indicated that the ligament crack was due to corrosion fatigue. The typical inside view of the affected header is given in figure-4.

Figure 4 : The typical inside view of the affected header The replica taken in the affected locations as well away from the affected location indicated no micro structural degradation. Also, the fillet welds connecting the stubs to the header when examined by MPI & LPI showed the welds to be in good condition. The sample tubes removed from SH section when subjected to uni-axial creep rupture test showed good remaining life for the operating parameters.

Dr V T Sathyanathan, M.E, Ph.D. BHEL, Trichy 62014

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3.1.3 Laboratory Analysis : The cut piece from SH outlet header was taken up for detailed analysis. The damage in the ligament location was attributed to corrosion fatigue. Corrosion damage was seen on inside surface of the header in other locations also. Though the replica taken from the header parent metal location did not reveal any microstructure degradation, the material was tested for tensile strength and yield strength which confirmed the suitability of material for further operation. The hardness measurements carried out at different locations confirmed no softening of material . Considering the metallurgical condition of the header and also based on the above laboratory results, it was decided to keep the unit in service for a limited period with the old header till replacement is arranged. The replacement decision was taken considering the corrosion damages seen on steam side surface of the header which was mainly attributed to collection of condensate during shut down. No drain provision was available in the original design and hence the condensate gets collected during shutdown . The new header supplied was provided with drain arrangement and the utility was recommended to avoid any collection of condensate during prolonged planned outage of the unit and also to maintain water regime as per suppliers recommendation. Thus the remaining life assessment study carried in the above unit indicated the possibility for continued operation with the existing components and it was necessary only to replace part of SH assemblies and the secondary SH outlet header with a new header . 3.2 CASE STUDY II. A 140 MW reheat , balanced draft type unit was taken up for study after a service period of 130,000 hours . The review of operational history indicated failures in cold reheat header stub as well as in ligament locations of reheat outlet header. The scope for assessment was finalised based on the failure history and on the outcome of discussions with station authorities. The work scope for remaining life assessment study covered the following.

Detection of hydrogen damage in water walls using attenuation principle. Inspection of cold reheat & hot reheat header internals by using fibrescope and also by ultrasonic testing . Replication at high temperature locations for evaluation of micro structural degradation. Inspection of desuperheater nozzle and liner. Sampling from different locations of SH & RH for metallurgical analysis.

The major findings from the study are given below: 1. Boiler drum Good condition. 2. Furnace tubes No hydrogen damage. 3. Economiser, Primary SH Adequate remaining life . & Conv.SH coils
Dr V T Sathyanathan, M.E, Ph.D. BHEL, Trichy 62014

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4. 5. 6. 7. 8.

Reheater Cold RH Header Hot reheat header Desuperheater Piping

Misalignment of coils and low remaining life Erosion in stub bends Ligament cracks particularly near the T piece. Enlargement of nozzle hole and also cracks in the liner plates. No microstructure degradation

The boiler which was designed for a maximum evaporating capacity of 450 T/hr was operating at lower load and with frequent failures in reheater. The deterioration in calorific value of fuel was the reason for load limitation. Visual inspection carried out on cold reheat header stubs showed rupture opening at few locations particularly near bend region. The ligament space at the header inside surface was checked using fiberscope and cracks were seen in circumferential ligaments particularly near T piece. ( both sides ) Ultrasonic testing using pulse echo with angle beam probe was done for checking the ligaments in other locations and for sizing the defect. The other ligament locations were found to be free from service cracks. The replica taken covering the weld and the heat affected zone location of the reheat outlet header revealed that the header material had not undergone any micro structural degradation. The decision to continue to operate with existing cracks in the ligament location adjacent to the T piece was carefully done after evaluation of the crack size and taking into consideration the duration required for arranging replacement. The header pipe thickness nearer to T piece weld was lower as compared to T piece thickness. The increase in stress at this location is likely to cause an early damage and any additional thermal stress due to mal functioning of spray system will aggravate the situation. In view of this, spray system was checked. The reheat steam temperature control was not proper because of damage to control valve seat. Till replacement of affected portion of header is carried out, the utility was recommended to take care of the following aspects. The spray control valve was recommended for replacement with a new valve. Thermocouples at cold reheat inlet header and outlet header were installed at critical locations and the temperatures were recommended to be monitored to avoid undue thermal stress . The cold reheat stubs which were found eroded were recommended to be replaced with fresh stubs. With the above, the utility was able to run the unit satisfactorily till replacement components were arranged. The life prediction carried out based on oxide scale measurement in reheater coils revealed lower life . The utility was recommended to replace the reheater coils also at the time of replacement of affected portion of reheat outlet header. The replacement of affected portion of the reheater outlet header and the coils were done in the subsequent shut down.
Dr V T Sathyanathan, M.E, Ph.D. BHEL, Trichy 62014

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Thus with the remaining life assessment study done in this unit, the utility could plan for life extension and the life extension programme for this unit could be done only by part replacement of specific components as identified above thereby the investment required for life extension programme could be minimised. 3.3 CASE STUDY III This case study covers the details of remaining life assessment done in one of the 110 MW units. The furnace construction was of refractory design, the air ingress in the boiler was more and this was causing poor efficiency in operation. While formulating the proposal for rehabilitation of this unit, this aspect was also taken into account. Accordingly, the refurbishment programme included activities to improve boiler efficiency and also the replacements necessary as identified in remaining life assessment study Evaporation SH design pressure SH design temperature Make Type Service hours 375 TONS/HR. 139 KG/CM2 540 C BHEL (Czech design) Balanced draft/Reheat 110,000.

The utility had carried out replacement of platen SH with modified design as the unit experienced frequent tube failures in platens. Also the economiser located in 2nd pass was replaced with modified design to minimise failures on account of gas side erosion. The major findings from the RLA study are given below: 1. 2. 3. 4. Boiler drum Water walls SH & RH coils Platen SH headers Existing drum found to be in good condition. Bow observed in different locations. The SH & RH coils were found to have adequate remaining life. Alignment disturbed. The common header connecting the branch headers when examined by replication, was found to have cracks in the heat affected zone of the fillet weld and also creep cavities were seen in the parent metal of the common header. SH & RH headers were found to be in good condition Piping was found to be in good condition, except for disturbance to hangers at few locations.

5. 6.

SH/RH headers. Piping

Dr V T Sathyanathan, M.E, Ph.D. BHEL, Trichy 62014

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The following major recommendations were given. Bowed water wall sections to be replaced Platen common header along with stubs for connecting the branch headers to be replaced. The details are shown in fig. 6 Alignment band provision for SH / RH coils. To minimise air ingress, it was recommended to replace waterwalls, horizontal pass and second pass with membrane / steam-cooled walls. ( Shown in thick line in fig 5 ) Also existing slag crusher system for furnace bottom ash handling was recommended for replacement with water impounded hopper to eliminate air ingress. 4.0 BHELS Experience In Life Extension Programme BHEL has been engaged in the design, manufacture and supply of boilers / steam generators from its manufacturing unit at Tiruchirapalli, since 1963. The range of boilers supplied by BHEL covers utility boilers from 30 - 500 MW capacities, and also industrial boilers for Steel plants, Fertiliser plants, Paper industry, Sugar plants etc. These boilers are capable of firing various fuels and industrial by-products like black liquor, blast furnace gas, coke oven gas, Corex TM gas, bagasse, rice husk etc. The design is based on the technical know-how obtained from various leaders in international market as well that developed through in-house R&D efforts. BHEL has been updating the boiler design over the years to suit our Indian conditions as well as the deteriorating coal quality. BHEL is also updating the design of boilers, by incorporating a number of state-of-the-art technologies and also utilising the feedback from over 500 BHEL boilers in operation in the country and abroad. These latest practices are adopted, wherever applicable, on the R&M packages proposed by BHEL. The list of such major R&M packages carried out by BHEL for the boiler proper (excluding ESP retrofit / augmentation) is given in Annexure 2. BHEL has also carried out retrofit / augmentation of more than 100 ESPs for utility/ captive power plants and in industry sectors. 4.0 CONCLUSION The rehabilitation of steam generators through life extension program results in increased availability, reliability, and plant load factor. As the new units are becoming more and more expensive , many new concepts and ingenious way of incorporating the present state - of - the - art technologies are brought through Renovation & Modernisation concept for old units through Life Extension Programme in which
Dr V T Sathyanathan, M.E, Ph.D. BHEL, Trichy 62014

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Remaining Life Assessment plays a vital role . BHEL has gained vast experience in this field and has rededicated itself to serve the customers by continuously updating its technology. 5.0 References: 1. CBIP Publication no. 168 : Thermal Power Stations in India 2. Sri K. Rajendran & Dr V T Sathyanathan - BHELs Approach / Experience in R&M of Boiler & Auxiliaries - Indian Institute of Plant Engineers Conference DIU - 1998 3. Dr. V T Sathyanathan & R Rajasekaran - Coal fired Boiler design for Reliability and Maintainability - Indian Institute of Plant Engineers Conference - Madras 1994 4. P.Nagamanickam , K. Rajendran & Dr. V.T. Sathyanathan - Residual life assessment of boilers - BHEL s experience - Conference on Residual lie assessment NTPC, Korba 1999 5. N. Ayodhi - RLA Based Life Extension Programme: BHELs Experience In Indian Utilities 6. Sri. A.M. Pagedar / CEA / Delhi - R&M of Thermal Units - Its economics LIPREX Seminar - Hyderabad 7. Dr V T Sathyanthan & K Sivaraman Residual Life Assessment and Renovation & Modernisation for Major Equipments of Captive Power Plants BHEL Journal, Vol. 21 No. 1, Feb. 2000.

Dr V T Sathyanathan, M.E, Ph.D. BHEL, Trichy 62014

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ANNEXURE
BHELs Experience in Rehabilitation & Modernisation OVERSEAS PROJECTS Sl. No. 01 Name of the Customer Tenaga Nasional Berhad, Malaysia Name of the Power Station and Capacity i) TJPS Stage I 2 x 60 MW ii) TJPS Stage II 2 x 60 MW iii) TJPS Stage III 3 x 120 MW Nature of Work Carried Out
Rehabilitation of boilers. Rehabilitation of turbine and generator auxiliaries. Replacement of total station controls and instrumentation with microprocessor-based system. Life assessment and extension survey. Incorporation of natural gas firing facility in three 120 MW boilers.

Remarks More than Guaranteed Efficiency achieved. Power consumption in FD/ID Fans achieved

02

Tenaga Nasional Berhad, Malaysia

SIPS 2 x 120 MW

Rehabilitation of boilers. Rehabilitation of turbine and generator auxiliaries. --- do -- Replacement of total station controls and instrumentation with microprocessor-based system. Life assessment and extension survey. Incorporation of natural gas firing facility in two 120 MW boilers. Rehabilitation of boilers. Rehabilitation of turbine and generator auxiliaries. Replacement of total station controls and instrumentation with microprocessor-based system. Life assessment and extension survey.

03

Tenaga Nasional Berhad, Malaysia

Prai 3 x 120 MW

--- do ---

Dr V T Sathyanathan, M.E.., Ph.D. BHEL, Trichy 62014

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Sl. No. 04

Name of the Customer General Electric Company, Libya General Electric Company, Libya

Name of the Power Station and Capacity Tripoli West TPS 60 MW boiler (Stein Industrie, France, make) Bengazi 8 x 160 t/hr boilers (Babcock Company make)

Nature of Work Carried Out

Remarks

Replacement of all bowed waterwalls. Replacement of superheaters, superheater supports. Revamping of burners. Revamping of ducts and insulation. Replacement of waterwalls. Replacement of refractory & insulation. Replacement of burners. Replacement of expansion bellows. Servicing of soot blowers, valves, fuel pumping and heating station. Servicing of fans. Replacement of APH elements and servicing. Renovation of controls and instrumentation. Chemical cleaning. Replacement of waterwalls, bank tubes. Replacement of insulation. Replacement of economiser. Servicing of valves, soot blowers. Servicing of burners. Servicing of fans. Revamping of controls and instrumentation.

05

06

General Electric Company, Libya

Zuera Desalination Plant 2 x 90 t/hr boilers (IDRO, TERMICI, Italy, make)

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Sl. No. 07

Name of the Customer General Electric Company, Libya

Name of the Power Station and Capacity Dhama TPS 3 x 120 t/hr boilers (Babcock, Germany, make)

Nature of Work Carried Out

Remarks

Replacement of waterwalls. Replacement of soot blowers. Replacement of refractory and insulation. Revamping of burners. Servicing of valves. Revamping of fuel system equipment. Servicing of fans. Servicing of airpreheaters and element replacement. Chemical cleaning. Replacement of complete furnace walls. Replacement of complete bank tubes. Replacement of superheater partly. Replacement of side waterwall headers. Replacement of damaged burners. Servicing of entire boiler including fan, APH, safety valves and other valves. Replacement of APH seals. Replacement of refractory & insulation. Replacement of water level indicator. Replacement of part-duct and expansion joints. Servicing of controls and instrumentation. Chemical cleaning.

08

Bangladesh Power Development Board, Bangladesh

Siddhirganj 1 x 50 MW (225 t/hr boilers) (CE, USA, make)

Dr V T Sathyanathan, M.E.., Ph.D. BHEL, Trichy 62014

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Residual Life Assessment and Life Extension Programme in Utility Boilers BHELs Experience

DOMESTIC PROJECTS (During the period 1990 to 1999) Sl. No. 01 Name of the Customer Neyveli Lignite Corpn. Ltd. (NLC) Name of the Power Station & Capacity 4 x 50 MW Unit nos. 2,3,4 & 5 Boilers of Russian make Nature of Work Carried Out
Complete pressure parts replacement (waterwalls, economiser, downcomer, SH, SH headers, DESH, entire MS piping etc. about 350 tons). All valves reconditioning / replacement. All non-pressure parts renovation. Measures for performance uprating/low capacity restoration. Pressure part replacement in waterwall, screen SH, Conv. SH, (Platen SH, redesigned with material upgrades). Burner performance uprating. APH (tubular) performance improvement. Other non-pressure parts renovation. Metal temperature scanner system introduction.

Remarks
Unit loaded to 235 t/hr (design 220 t/hr). Exit gas temperature reduced from 190C to 140 C.

02

Steel Authority of India Ltd (SAIL)

Bokaro Steel Plant 3 x 220 t/hr Unit nos. 3,4 & 5 Boilers of Russian make

Boiler loaded to full capacity.

03

Bihar State Electricity Board (BSEB)

Unit nos. 1-4 & 5-6 8x50 MW Boilers

Replacement of complete downcomer pipes. Replacement of waterwall tubes partial. Replacement of superheater - modified design. Replacement of economiser blocks - modified . Replacement of main steam piping. Replacement of airheater blocks.

Work under progress.

Dr V T Sathyanathan, M.E.., Ph.D. BHEL, Trichy 62014

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Residual Life Assessment and Life Extension Programme in Utility Boilers BHELs Experience

Sl No. 04 05

Name of the Customer APSEB RSEB

Name of the Power Station & Capacity Kothagudem TPS 2 x 110 MW Unit nos. 7 & 8 Kota TPS 2 x 110 MW Unit nos. 1 & 2 Ennore 2 x 110 MW Unit nos. 3 & 4 Bhilai Steel Plant 2 x 150 t/hr Boilers of Russian make Kothagudem 2 x 110 MW Unit nos. 5 & 6

Nature of Work Carried Out

Remarks
About 50 C gas temperature reduction achieved. Full parameters achieved since 1995.

06

TNEB

Work under progress.

07

SAIL

Non pressure part renovation. Total downcomer /upriser replacement DESH replacement. SH headers replacement. Work under progress.

08

APSEB

Complete pressure part re-engineering (tangent tube waterwall to membrane tube waterwall). Performance uprating (lost capacity restoration). Non pressure part renovation. Milling system capacity upgradation.

09

HSEB

Panipat TPS 4 x 110 MW Unit nos. 1,2

Work under progress.

Dr V T Sathyanathan, M.E.., Ph.D. BHEL, Trichy 62014

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Residual Life Assessment and Life Extension Programme in Utility Boilers BHELs Experience

Sl No. 10

Name of the Customer UPSEB

Name of the Power Station & Capacity Obra Unit no. 11 200 MW

Nature of Work Carried Out

Remarks Lost capacity of boiler restored.

11

SFC, Kota

2x90 T/Hr Boilers

12

13 14

Gujarat Narmada Valley Fertiliser Corporation, Bharuch IOC, Mathura IOC, Haldia

3x180 T/Hr VU 40 Boilers

Lost capacity enhancement. Higher size mill replacement. Performance review for low-grade coal. Fuel conversion additional gas firing facility. Forced drain system for soot blowers (State-of-the-art improvement).

3x150 T/Hr VU 40 Boilers 3x125 T/Hr Boilers

Conversion of boiler for 100% natural gas firing.

Capacity enhancement by more than 15% carried out successfully. Fuel conversion implemented and successfully tested at full load. Forced drain system for soot blowers supplied and commissioned. Conversion completed and performance proved. Burner retrofit completed and working.

Low NOx burner retrofit.

Dr V T Sathyanathan, M.E.., Ph.D. BHEL, Trichy 62014

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