(3 5 ADVANCED BOILER INSPECTION TECHNIQUES 2011 Contents 1. Reliability & Availability. Industry overview Boiler/Steam Generator. Development and History of Supercritical boilers: ... Boiler Water Treatment, Emissions Performance NOx Availability Improvements at F 2. Risk management. Data Driven Planning Risk Driven Project Planning and Execution.... Risk Driven Project Process \ Value-based Management Formal repair selection cri Ranking of priorities. ae FAILURES AND NEAR FAILURES IN FOSSIL PLANTS... COSTS ASSOCIATED WITH BOILER TUBE FAILURES...... REPEAT BOILER FAILURES... Proper Failure analysi Choice of Corrective /Preemptive Action. Problem Defi Multidiscipline Approach Permanent Engineered Solutions Boiler Condition Assessments how and Why? ..+0- 3. Human Resources Equipment required for in plant boiler inspection teams. eet Utilization of supplemental Boiler Inspection Team Members... 4. Outage management. Cost Control. i (©1987-2011 UDC all rights served United Dynamics “AT” 2681 Coral Ridge Rd. Brooks, KY 40108 Voice 502.987.7525,(2 5. 6 7, g ADVANCED BOILER INSPECTION TECHNIQUES 2011 Quality Assurance Data forms. Inspection Check Lists Technical procedures... Planned Outage Preparation. Inspection Methods... Boiler Tube Repair and Replacement teil 61 Known Boiler Specific Failure Mechanisms .. Recommended Actions... Inspection Photography... Report preparation Forced Outage Procedures. Operational Factors affecting failures... Cycling the boiler. Start up shut down ramp rates... SHORT TERM OVERHEAT..... 78 Ligament cracking i .-80 DISSIMILAR METAL WELD (DMW) CRACKING. on ( DEW-POINT CORROSION... SOOTBLOWER (Wall & Retractable) EROSION .... 103, ‘Thermal fatigue (Quench cracking) from water lances and water €aNNONS 110 7 Craze cracking (alligator Ride).orennernnnennn FALLING SLAG INTO HOPPER BOTTOM (coutant) CREEP, HIGH TEMPERATURE 124 Fuel & Burners. Socfeneeeteete ts 138 FIRESIDE FURNACE CORROSION ..... 141 Coal ash corrosion 43 ASH CORROSION 144 COAL PARTICLE EROSION. 153 FLY ASH EROSION PRB Coal Fuel... ‘Component Replacements 170 Economic justification tips 170 (©1987-2011 UDC all rights resered United Dynamics “AT 2681 Coral Rilge Rd Brooks, KY 40108 Voie 502.957.7525,Ms ADVANCED BOILER INSPECTION TECHNIQUES 2011 Component Replacements \ Replace versus Repair the How's and WAYS... Replacements versus Repairing... 8. Selection and installation of pressure part components. 7 STRENGTH BASIS OF MATERIAL SELECTION OF BOILER PRESSURE PARTS. soe gy. OTHER CONSIDERATIONS IN MATERIALS SELECTION AND USE 9. Commercial issues of procurement of new pressure parts Inspection of new fabrications in the assembly shop QA/QC. CREEP, LOW TEMPERATURE. 10. BOILER CHEMISTRY. Boiler Cycle chemistry Common water chemistry problems and their consequences, The elements of a good water chemistry program. seetease 189 Deposit Control... Conventional phosphate treatmer Chelant treatment: Boiler off line lay up procedures... Chemical cleaning’ Deposit Loading. 197 Contamination-Required Cleaning: 198 STRESS CORROSION CRACKING. 199 CORROSION FATIGUE. 201 PITTING... CAUSTIC CORROSION / GOUGING ACID PHOSPHATE CORROSION... HYDROGEN DAMAGE. II, STEEL APPLICATIONS AND USE. Metallurgy 12, Hydrostatic testing yes or no? ‘BOILER FILL WATER TEMPERATURE REQUIREMENTS. 13. Repairs se 234 ‘Tube replacement vs. repai 234 Pad Weld / Overlay Applications. 236 Copper (Weld Repair Caution) 239 3 (©1987-2011 UDCall hts esered United Dynamics “AT* 2681 Coral Ridge Rd. Brooks, KY 40109 Voce: 50257-7525,