Failure Investigation of Boiler Water Wall Tubes of a Thermal Power Station

Munda, Parikshit; Kumar, S. Mohan; Prakash, Alok; Husain, Murtuja; Rajnikanth, V.; Chowdhury, Sandip Ghosh

doi:10.1007/s11668-015-0055-0

Cited by 20 publications

(8 citation statements)

References 8 publications

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“…This evidence is found and presented in Figures 7 and 8. Long-term overheating can be occurred due to the presence of scale inside the tube surface, which blocks heat transfer from the outside surface to condensate inside the tube 2,16,17) . scale Figure 13.…”

Section: Discussionmentioning

confidence: 99%

“…There are so many methods to conduct failure analysis, but the most popular and complete method is the "root cause analysis method" 2) . Root cause analysis is a method that observes all of the possible causes that can make the system or components fail 2,3) . By considering all aspects that have the potential to be the main cause of failure therefore many data should be collected, including the chronology of failure, operational records, operational parameters, and also some examinations and tests on the failed component.…”

Section: Introductionmentioning

confidence: 99%

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Implementation of Root Cause Analysis Method to Investigate Failure of Front Wall Tube Boiler

Febriyanti

Suhadi

Sari

2023

Majalah Ilmiah Pengkajian Industri

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Root cause analysis is a method that observes on all of possible causes that can make the system or components fail. This research is implemented such method to investigate failed front wall tube on the boiler. The purpose of this research is to find out the main cause of failure on front wall tube in order to avoid similar problem in the future. Â With considering all aspects that have potential to be the main cause of failure therefore,Â many tests and examinations are done including visual test, fractography, metallography, chemical analysis, hardness test, SEM and EDS analysis. Â Examination result on the fracture surface shows two bulges on a tube and some longitudinal cracks spread on bulges outside surface area. While thick scale is also found on inside surface of these bulges. Moreover microstructure and hardness changes are also found on this area. Â From all of tests result that obtained it is concluded that the main cause of failure is the presence of scale that reduce heat transfer, so that local over heating occurred.Â Consequently, its tensile strength in this area is decreased and finally tube could not support operational pressure and deformed to make bulge. Â Â Â Â Root cause analysis is a method that observes on all of possible causes that can make the system or components fail. This research is implemented such method to investigate failed front wall tube on the boiler. The purpose of this research is to find out the main cause of failure on front wall tube in order to avoid similar problem in the future. Â With considering all aspects that have potential to be the main cause of failure therefore,Â many tests and examinations are done including visual test, fractography, metallography, chemical analysis, hardness test, SEM and EDS analysis. Â Examination result on the fracture surface shows two bulges on a tube and some longitudinal cracks spread on bulges outside surface area. While thick scale is also found on inside surface of these bulges. Moreover microstructure and hardness changes are also found on this area. Â From all of tests result that obtained it is concluded that the main cause of failure is the presence of scale that reduce heat transfer, so that local over heating occurred.Â Consequently, its tensile strength in this area is decreased and finally tube could not support operational pressure and deformed to make bulge. Â Â Â Â

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Section: Discussionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Implementation of Root Cause Analysis Method to Investigate Failure of Front Wall Tube Boiler

Febriyanti

Suhadi

Sari

2023

Majalah Ilmiah Pengkajian Industri

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“…8,9 In order to understand the crack failure of the furnace channel, there is no denying that the investigation of the thermal stress and strain distribution not only is of paramount importance to avoid such malfunction but also improves the mechanical reliability of the furnace. [10][11][12][13] Fluidstructure interaction (FSI) procedure is subjected with a wide range of application engineering and deals with the interaction between the fluid and the solid domain over nonpermeable interfaces. 14 Because the flow inside channel has great influence on the static performance of the complete water wall, the method performs adequate consideration of the flow temperature and pressure inside channel for the initial condition such as FSI and is necessary for the accurate investigation of the static characteristic.…”

Section: Introductionmentioning

confidence: 99%

“…Therefore, broad scientific researches paid attention to the materials that are supposed to enhance the capacity of high‐temperature resistance 8,9 . In order to understand the crack failure of the furnace channel, there is no denying that the investigation of the thermal stress and strain distribution not only is of paramount importance to avoid such malfunction but also improves the mechanical reliability of the furnace 10–13 . Fluid–structure interaction (FSI) procedure is subjected with a wide range of application engineering and deals with the interaction between the fluid and the solid domain over nonpermeable interfaces 14 .…”

Section: Introductionmentioning

confidence: 99%

A thermal stress analysis of fluid–structure interaction applied to boiler water wall

Zhang

Yang

Nie³

et al. 2020

Asia-Pacific J Chem Eng

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Fluid-structure interaction (FSI), the combination of computational fluid dynamics and computational solid mechanics, is considered as a procedure to determine the stress or strain of the solid under the influence of flow movement. Common parameters such as pressure and temperature that existed in the fluid solver and solid solver are the core factors of date communication in FSI. This work investigated the thermal stress and deformation distribution of the vapor segment of the water wall by numerical simulation under two typical conditions of the 660-MW boiler. The ideal condition and the case with the oxide scale inside were compared to realize the peculiarity of parameter distribution. The results revealed that the peak temperature of water wall was

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“…While dealing with failure investigation of boiler tubes, there are several mechanisms that can cause failure of the boiler tubes such as creep, thermal fatigue, corrosion and overheating [3][4][5][6][7][8][9][10][11][12][13]. Stress rupture due to short-term overheating is one of the failure mechanisms in thermal power plants.…”

Section: Introductionmentioning

confidence: 99%

Evolution of Microstructure During Short-term Overheating Failure of a Boiler Water Wall Tube Made of Carbon Steel

Munda

Husain

Rajinikanth

et al. 2018

J Fail. Anal. and Preven.

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This paper highlights the evolution of different microstructures during short-term overheating failure of a boiler water wall tube made of SA210 Grade C steel. Shortterm overheating failure of the boiler tube caused fish mouth rupture with thin lips, along the longitudinal direction of the tube with extensive tube bulging. Microstructure examination revealed elongation of grains at the fracture signifying plastic deformation due to hoop stress becoming equal to the flow stress of the tube at the elevated temperature. Overheating caused degeneration of the initial ferrite-pearlite microstructure. Spheroidization and coalescence of carbides occurred in the ferrite matrix from the initial ferrite-pearlite microstructure of the boiler tube near the ruptured region. Moreover, the formation of bainite microstructure at the fracture fish mouth opening indicates heating above the eutectoid temperature (lower critical temperature) of the tube material.

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Failure Investigation of Boiler Water Wall Tubes of a Thermal Power Station

Cited by 20 publications

References 8 publications

Implementation of Root Cause Analysis Method to Investigate Failure of Front Wall Tube Boiler

Implementation of Root Cause Analysis Method to Investigate Failure of Front Wall Tube Boiler

A thermal stress analysis of fluid–structure interaction applied to boiler water wall

Evolution of Microstructure During Short-term Overheating Failure of a Boiler Water Wall Tube Made of Carbon Steel

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