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    SHRH Flyash Erosion

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    Nanda
    Tube wall erosion can occur due to high velocity ash particles impacting tube surfaces in boiler systems. The ash particles contain abrasive materials like quartz and pyrites that remove the protective oxide scale from tube walls and cause thinning. This thinning can eventually lead to longitudinal ruptures in the tubes. Specific areas of boilers like areas with flow changes or plugged passages are more susceptible. Inspection techniques like visual testing and ultrasonic testing can be used to locate erosion and determine its extent.

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    SHRH Flyash Erosion

    Uploaded by

    Nanda
    22 views1 page
    Tube wall erosion can occur due to high velocity ash particles impacting tube surfaces in boiler systems. The ash particles contain abrasive materials like quartz and pyrites that remove the protective oxide scale from tube walls and cause thinning. This thinning can eventually lead to longitudinal ruptures in the tubes. Specific areas of boilers like areas with flow changes or plugged passages are more susceptible. Inspection techniques like visual testing and ultrasonic testing can be used to locate erosion and determine its extent.

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    Tube wall erosion can occur due to high velocity ash particles impacting tube surfaces in boiler systems. The ash particles contain abrasive materials like quartz and pyrites that remove the protective oxide scale from tube walls and cause thinning. This thinning can eventually lead to longitudinal ruptures in the tubes. Specific areas of boilers like areas with flow changes or plugged passages are more susceptible. Inspection techniques like visual testing and ultrasonic testing can be used to locate erosion and determine its extent.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    22 views1 page

    SHRH Flyash Erosion

    Uploaded by

    Nanda
    Tube wall erosion can occur due to high velocity ash particles impacting tube surfaces in boiler systems. The ash particles contain abrasive materials like quartz and pyrites that remove the protective oxide scale from tube walls and cause thinning. This thinning can eventually lead to longitudinal ruptures in the tubes. Specific areas of boilers like areas with flow changes or plugged passages are more susceptible. Inspection techniques like visual testing and ultrasonic testing can be used to locate erosion and determine its extent.

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    © All Rights Reserved
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    of 1

    Total Boiler Management™ - Proprietary Documentation

    SH/RH Flyash Erosion

    Picture here if available

    Failure Mechanism:
    Tube wall wastage by the impact of abrasive particals in the gas stream and by removal of protective fireside oxide that increases the oxidation rate
    Damage Cause:
    High velocity ash with highly concentrated erosive impurities (Quartz and Pyrites) impacts the OD of tubing downstream resulting in the removal of the protective oxide
    scale and tube metal that causes accellerated wall thinning that, with normal primary operating stresses, eventually results in tube failure.

    Damage Mode:
    Ductile, thin-edged, longitudinal "fish mouth" rupture
    Possible Root Cause(s):
    C1 - Excessive local (non-uniform or turbulent) gas flows which entrain large volumes of erosive fly ash particles and direct them onto the tube surface
    Damage Precursors:
    P1 - Burnishing or polishing of tube outside surfaces facing the gas flow.
    P2 - Very localized wear and wastage flats.
    P3 - Fresh rust on tubes after unit washing adjacent to blockage of boiler gas passages.
    P4 - Arbitrary addition of deflection baffles without CAVT modeling
    P5 - Change to a coal with higher ash content and / or abrasion propensity
    P6 - Operating above MCR with excessive and / or unbalanced air and gas flow
    How damage can be identified, verified and its extent determined:
    CAVT is "best practice" for initiating defenses to minimize potential damage resulting from flyash erosion. Once damage occurs, CAVT should again be employed to
    optimize those defenses in addition to employing VT to locate, UT to quantify wall wastage and both to characterize the distribution and extent of wear. Weld Gauges
    may be helpful to measure damage in confined areas.
    Where damage normally occurs:
    Near gas-direction changes, near plugged or fouled passages; where previous baffles had been installed. Since flyash is normally more erosive at lower temperatures
    particular attention should be paid to horizontal sections in the convection pass. Inlet areas of reheaters are common wastage sites because of higher gas velocities and
    eddying present there. Areas in superheaters where slagging is pronounced are common problem areas because gas flow in the narrow gas channels increases.

    Damage Features:
    Burnishing or polishing of tube outside surfaces facing the gas flow.
    Very localized wear and wastage flats. Fresh rust on tubes after unit washing adjacent to blockage of boiler gas passages.
    Inspection Features:
    Severe, yet smooth, widespread tube and header wastage along with erosive wear of surrounding structures and attachments.
    Materials normally subject to damage:
    ASME Section 1 Carbon Molybdenum (SA-209 T1, SA-209 T1a), Chrome Molybdenum (SA-213 T11, SA-213 T22) and Stainless Steel (SA-213 321H, SA-213 347H, SA-313
    304H) tubes
    The unit's status when damage begins:
    In-Service
    Definitions:
    Failure: Any change in a component that causes it to be unable to perform it's intended function
    Damage: Any change imposed upon a component that substantially reduces its useful life prior to failure
    Damage Mode: The appearance, manner or form which advanced component damage ultimately manifests itself.
    Damage Mechanism: How and or why damage occurs in a chemical of metallurgical terms
    Damage Cause: The cause of a damage event or damage mode
    References: Boiler Tube Failures: Theory and Practice, Naughton, Dooley 1996, The Nalco Guide to Boiler Failure Analysis, Port, Herro 1991, Metallurgical Failures in Fossil
    Fired Boilers, French 1993, Mineral Impurities in Coal Combustion, Raask 1985

    © 2010 by P&ROSolutions, Inc. All rights reserved. Unauthorized reproduction, distribution, or use is strictly prohibited.

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