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Sl. No. Item
1 Unit No
2 Date & Time of BTL detection
3 Date and time of shutdown
Date & time of Boiler Light up after
4 attending BTL
5 Date & time of Unit Synchronization
8 First hand Failure description
6 Primary failure location

7 Secondary damages if any

photographs of the primary and

9 secondary damage in situ
10 Tube original OD / Thickness

11 Tube material & composition

12 Yield point of original material

13 Type of Failure
14 Cause of Failure
Original Service condition of the tube at
15 MCR (Pressure, temperature, Flue Gas
temperature)
Last replacement date of the failed
16 portion ( if any ) in the same zone
Attachment of drawing with marking on
17 the failed portion
18 Details of repair & no. of joints
Recommendation for corrective action if
19 any

20 Recommendation to prevent recurrence

PIC: 1
PRIMARY FAILURE
 Pin hole leakage from
tube no. 01 of 11th Eco
Coil (Module 06)

PIC: 1
SECODARY FAILURE

Secondary damage of
tube no. 02 of 11th Eco
Coil (Module 06)
PICTURE: 2
fuxe / DAMODAR VALLEY CORPORATION

dsUnz / BOKARO THERMAL POWER STATION

Detail Description
BTPS-A U#1
-
10/23/2018 2:00
-
24-10-2018 21:55(PWC return )
Unit was taken out of bar due to BTL
Pin hole leakage from tube no. 42 & 43 of rear S-Panel (water
wall) and tube no. 01 of 11th Eco Coil (Module 06)
Tube no. 40, 41 & 44 of rear S-Panel (water wall) and tube no.
02 of 11th Eco Coil (Module 06)

Attached

51/5.6 mm & 38.1/4.5 mm

SA 210 Gr C (S-Panel) & SA 210 Gr A1 (Eco O/L Coil to Hdr

stub joint)

Erection weld joint

Weld defect

NA

14 joints
Thorough physical inspection of joints to be carried in
overhauling of the unit.
Thorough physical inspection of joints to be carried in
overhauling of the unit.

PIC: 1
RIMARY FAILURE
 44
40 43
41 42

PIC: 1
CODARY FAILURE

43 44
42
41
40
 Cause Codes of Boiler Tube Failures
Sno
Main Cause Auxiliary Cause
* Incorrect circulation
*Steam Blanketing
*Incorrect Alloy
1 DD -Defect,Design
*Thermal Stress-Expansion retricted

* inadequate Pressure Drop

*Porosity-slag inclusions
*Over Penetration
2 DW- Defect Welding *Lack ofadequate Bonding
*Cracks-inadequate stress relieving

*Laminations,Inclusions in Tube wall

3 DM-Defect, Material
* Inferior Material

*Caustic Attack
*Hydrogen Fatigue
4 IC- Internal Corrossion *Oxygen Attack
*Stress Corrossion cracking
*No details given

*Sootblower Erosion
*Flue gas Erosion
5 ED - External Deterioration *Steam Impingement
*Flame Impingement
*External Corrossion

*Water quenching-ash pit water

*Mechanical Stress- tube vibration
*Debris blocking tube
6 MS-Miscellaenous * Long Term creep
* Operator error
*No cause given
*Others