U # 6 OH Exception

15/05/2006

U # 6 OH Exception
Steam erosion due to W/W soot blowers near corner 2 & 6 Probable causes of steam erosion : Improper draining of S/B header before start of soot blowing Problem in S/B rotary motion mechanism Steam kept charged in case of S/B gets stuckup inside furnace S/B alignment problem due to missing furnace cap

U # 6 OH Exception
Steam erosion was observed in radiant S/H inlet header (L4) : no of bend tubes got eroded, complete set is required to be replaced.

Radiant S/H I/L header (L4)

Radiant S/H I/L header (L4)

Radiant S/H I/L header (L4)

U # 6 OH Exception
Reheater final stage tubes connecting to outlet header (in the pent house) are having blackish layer. This is due to long term overheating (by conduction) Hardness has not changed much. Reason : Probable cause is secondary combustion due to air ingress through pent house.

U # 6 OH Exception
1 9 16 24 31 39 46 54 61 69 76 84

Blakish layer in middle coils 42,43,44

Going to 2nd pass

U # 6 OH Exception
1 3 5 7 9 11 13 15 17 19 21 23

Platen-I Middle

I/L

O/L

I/L

O/L Going to Platen II Platen-I Final

U # 6 OH Exception
1 3 5 7 9 11 13 15 17 19 21 23

Platen-II Middle

I/L

O/L

I/L

O/L

Going to R/H panel Platen-II Final

CW Outlet duct

CW Outlet duct

CW Outlet duct

CW Outlet duct

CW Outlet duct

U # 6 OH Exception
CBA of CW inlet duct painting CW flow data (FY 2005-06) U# Pre O/H Post O/H Gain #1 20490 22300 1810 #2 21320 23010 1690 #3 20580 22600 2020 #4 19900 22170 2270 Average flow improvement ~1950 (where Black bituminous painting was not done)

U # 6 OH Exception
CBA of CW inlet duct painting CW flow data (FY 2005-06) U# Pre O/H Post O/H Gain #5 20130 23255 3125 (where Black bituminous painting was done)

Additional gain in CW flow = 3125 9150 = 1175

U # 6 OH Exception
CBA of CW inlet duct painting With increase of 1000 M3/Hr CW flow there will be gain in CW temp rise equivalent to 0.3 deg C & corresponding gain in Condenser vacuum and Heat rate will be 0.00175 Ksc (1.3 mmHg) and 2.1 Kcal/Kwhr daily monetary gain (For 100% PLF) will be ~Rs. 3175/= Cost of painting is 100000/Hence, payback period is 31 days

U # 6 OH Observations
Reheater 3rd Stage
Notch observed in panel no. 83 at first bent. 02 nos. steam cooled wall infront of top binder of panel no. 84 rubbing the steam-cooled wall. The binder is to be cut. The spacers provided at front side is rubbing with the coil, to be cut and provided below the coil where shield is available with the tube

U # 6 OH Observations
Reheater 2nd Stage
Out of side panel no. 83 centre bent has been notched. Steam cooled wall front side tube no. 2,3,4,5,6,7&8 (from RHS) are to be replaced at eco top. Eco top steam cooled wall tube no. 6 to 10 are to be replaced Steam cooled wall above economiser at rear wall tube no. 6,7,8,9&10 are to be replaced.

U # 6 OH Observations
Reheater 2nd Stage
LHS steam cooled wall above economiser tube no. 6 to 1 notches observed. Front steam cooled wall above economiser tube 4,5&6 notched observed. Rear side steam cooled wall above economiser tube no. 3,4,5,6,7,8&9 notches observed In RHS steam cooled wall 4th tube from rear side notches observed.

U # 6 OH Observations
Hanger Tubes
Row no. 6 hanger no. 1 notches observed. Row no. 5 hanger no. 72 notches observed. Row no. 6 hanger no. 72 notches observed. Row no. 3 hanger no. 4 to be replaced. Row no. 6 hanger no. 29 to 31 fitting observed. 83 tubes have been identified for rectification

U # 6 OH Observations
Radiant Super heater
Soot blower is rubbing with radiant super heater tubes. In radiant super heater bents rubbing the tube in some locations. Radiant super heater hooks are tapping water wall tube that has to be protected at few locations, the supports are radiant super heater damaged. Superheater panel no. 11 near the top binder erosion observed.

U # 6 OH Observations
Burner area
Top oil burner plate in each panel block got damaged. To be rectified. Oil burner air guide pipe badly damaged at the top most of corner and partially damaged at bottom blocks. Oil gun guide pipe at the furnace side is melted. Refractory is to be provided for panel side tubes. 05 nos. of tubes are identified for replacement.