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ANALYSIS OF FLY ASH ERROSION IN WATER TUBE BOILERS

PROJECT REPORT Submitted by S.PALANISAMY G.DHANAPAL P.SREEDHARAN K.KANI (10TME027) (10TME007) (10TME048) (10TME014)

in partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING
in

MECHANICAL ENGINEERING

GOVERNMENT COLLEGE OF ENGINEERING, SALEM - 636 011. (An Autonomous Institution Affiliated to Anna University, Chennai) NOVEMBER 2013 GOVERNMENT COLLEGE OF ENGINEERING, SALEM - 636 011 (An Autonomous Institution Affiliated to Anna University, Chennai) BONAFIDE CERTIFICATE Certified that this project report ANALYSIS OF FLY ASH ERROSION IN WATER TUBE BOILERS is the bonafide work of

S.PALANISAMY G.DHANAPAL P.SREEDHARAN K.KANI Who carried out the project work academic year 2013- 2014

(10TME027) (10TME007) (10TME048) (10TME014 under my supervision during the

SIGNATURE Dr. R.Vijayan, Ph.D., HEAD OF THE DEPARTMENT PROFESSOR

SIGNATURE Prof. K.KAVITHA,M.E., SUPERVISOR ASSISTANT

Department of Mechanical Engineering, Government College of Engg, Salem - 636 011.

Department of Mechanical Engineering, Government College of Engg, Salem - 636 011.

Submitted for the Project Viva-Voce examination held at the Government College of Engineering, Salem-11 on 23-10-2013

Internal Examiner DECLARATION

External Examiner

We affirm that the Project Report titled ANALYSIS OF FLY ASH ERROSION IN WATER TUBE BOILERS being submitted in partial fulfilment of the requirements for the award of Bachelor of Engineering is the original work carried out by us. It has not formed the part of any other Project Report or dissertation on the basis of which a degree or award was conferred on an earlier occasion on this or any other candidate.

S.PALANISAMY G.DHANAPAL P.SREEDHARAN K.KANI

(10TME027) (10TME007) (10TME048) (10TME014

I certify that the declaration made by the above candidates is true to the best of my knowledge.

Date:

External Guide
Mr. K.KANNAN Assistant Executive Engineer Boiler Maintenance Mettur Thermal Power Station Mettur dam
ABSTRACT

Fly ash particles entrained in the flue gas from boiler furnaces in coal-fired power stations can cause serious erosive wear on steel surfaces along the flow path. Such erosion can significantly reduce the operational life of the boiler components. A mathematical model embodying the mechanisms of erosion on behaviour has been developed to predict erosion rates of coal-fired boiler components at different temperatures. Various grades of steels used in fabrication of boiler components and published data pertaining to boiler fly ash have been used for the modelling. The model incorporates high temperature tensile properties of the target metal surface at room and elevated temperatures and has been implemented in a user-interactive in-house computer code to predict the erosion rates of various grades of steel. The model is calibrated with plant and experimental data generated from a high temperature air-jet erosion-testing facility. It is hoped that the calibrated model will be useful for erosion analysis of boiler components.

ACKNOWLEDGEMENT

Apart from the efforts of us, the success of any project depends largely on the encouragement and guidelines of many others. We take this opportunity to express our gratitude to the people who have been instrumental in the successful completion of this project. We take immense pleasure in thanking our beloved Principal

Dr.R.S.D.WAHIDA BANU, Ph.D., Government College of Engineering, Salem for permitting us to do this project. We wish to express our deep sense of gratitude and indebtedness to Dr . R.VIJAYAN, Ph.D., Professor and Head of the Department, Department of Mechanical Engineering for his guidance and useful suggestions, which helped us in completing the project work in time. I express my sincere and hearty thanks to our beloved project guide Prof. K.KAVITHA, M.E., Assistant Professor, Department Of Mechanical

Engineering, for his gracious encouragement, guidance and striking suggestions from time to time to complete this project in the grand success. I extend my sincere thanks to our beloved Class Advisor Dr.R.VIVEKANANTHAN, Ph.D., Assistant Professor, Department Of Mechanical Engineering, who has given encouragements and good suggestions at times to complete the project effectively. We would also thank our Institution and our faculty members without whom this project would have been a distant reality. We also extend our heartfelt thanks to all the members who contributed to this project, which was vital for the success of our project.
TABLE OF CONTENT

CHAPTER:N O ABSTRACT LIST OF TABLES LIST OF FIGURES INTRODUCTION

TITLE

PAGE: NO iv ix x 1 3 3 5 7 7 7 8 9 10 11 13 14

1. 2.

LITERATURE SURVEY 2.1 TUBE FAILURES 2.1.1 Suggestions for Avoiding Such Failures 2.1.2 Boiler Tube Watersides Corrosion Stress Failures 2.1.3 Boiler Tube Firesides Corrosion and Erosion Failures 2.1.4 Boiler Tube Cold-Side Failure OVERVIEW OF COAL ASH DEPOSITION IN BOILERS 3.1 Statement Of The Problem 3.2 Fundamental Considerations In Ash Deposition 3.3 Assessment Of Traditional Predictive Methods 3.4 Areas Of Uncertainty

3.

4.

COAL ANALYSIS

5.

4.1 Proximate Analysis 4.2 Mathematical Erosion Model 4.2.1 Cutting Wear 4.2.2 Plastic Deformation Wear 4.2.3 Numerical Implementation 4.3 Discussion 4.3.1 Volatile Matter 4.3.2 Ash 4.3.3 Fixed Carbon 4.3.4 Ultimate Analysis 4.4 Materials Contained In A Boiler 4.4.1 Carbon And Hydrogen 4.4.2 Nitrogen 4.4.3 Sulphur 4.4.4 Ash 4.4.5 Oxygen 4.4.6 Silica Oxide 4.4.7 Alumina 4.4.8 Iron Oxide And Alumina (R2O3) STEP INVOLVED 5.1 Geometric Modelling Of The Boiler 5.2 Meshing 5.3 Porous Media Approach 5.3.1 Cold Air Velocity Test 5.4 Simulation Of CAVT Using Fluent EXPERIMENTAL WORK & RESULTS 6.1 Visual Examination 6.2 Tensile Test 6.3 Hardness Test 6.4 Microscopic Test 6.5 Chemical Composition Of Tube Material 6.6 Water Analyses And Treatment 6.7 Fuel Analyses 6.8 Deposits And Oxides Analysis 6.9 Discussion 6.9.1 Tensile Test Results 6.9.2 Hardness Test Results 6.9.3 Microscopic Test Results 6.9.4 Chemical Composition Of The Tube Material Results 6.9.5 Water Analysis And Treatment 6.9.6 Chemical Composition Analysis 6.9.7 Fuel Analysis 6.9.8 Deposits And Oxides Analyses 6.10 Investigation

14 14 15 18 19 20 21 21 21 21 22 22 22 22 22 22 22 23 23 24 24 24 25 25 25 30 30 30 30 30 31 31 31 31 32 32 34 34 35 35 36 36 37 38

6.

7. 8. 9.

6.10.1 Macro-Investigation 6.10.2 Micro Structural Investigation FAILURE MECHANISMS AND ROOT CAUSE RECOMMENDATION CONCLUSION REFERENCES

38 40 42 43 45 46

LIST OF TABLES
TABLE NO
4.1 4.2 6.1 6.2 6.3 6.4 6.5 8.1

DESCRIPTION
Chemical composition of various grades of steel Chemical composition typical boiler fly ash sample Chemical composition of investigated samples Chemical composition of investigated samples Wall thickness at different locations at tube sample chemical composition of received tube samples hardness measurement at different locations Bottom ash analysis

PAGE NO
16 17 36 36 39 40 40 43

9 8.2 Fly ash analysis 44

LIST OF FIGURES
FIGURE NO
1.1 2.1 2.2 2.3 4.1 4.2 4.3 4.4 4.5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 6.1

DESCRIPTION
Coal-Fired Boiler Assembly Tube Failure Due To Over Heating Tube Failure Due To Long Duration Over Heating Relation Between Blow Down And Feed Water Moisture Analysis Of Ash Variation Of Erosion Rate With Impingement Velocity (Steel) Variation Of Erosion Rate With Impingement Velocity (Cr-1MoV Steel) Variation Of Erosion Rate With Temperature Of Target Material (Carbon Steel) Variation Of Erosion Rate With Impingement Angle At Room Temperature And Elevated Temperatures At 573K And 873K Velocity Vectors At Static Pressure Meshing Contours Of Total Pressure Contours Of Velocity Magnitude Velocity Vectors At Static Temperature Relative Velocity Coloured By Modified Turbulent Viscosity Meshing Wall Thinning Erosion

PAGE NO
1 4 4 6 14 20 20 21 23 26 26 27 27 28 28 29 32

10 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 Views Of The Ruptured Tube Cross-Section At The Beginning Of The Fracture View Of The Ruptured Tube Cross-Section At The Center Of The Fracture 6.4 View Of The In-Service-Non-Ruptured Tube Cross-Section Showing Good Tube Ovality. View Of The Received New Showing Tube Good Ovality View Of The New Tube Cross-Section Ruptured Tube In-Service-Non-Ruptured Tube 200x, Tube Fireside, Near Outer Surface, Thermal Decomposition 200x, Tube Cold Side, Near Inner Surface, Thermal Decomposition 33 33 34 34 34 37 37 41 41