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    NDT Technology in Boiler & RLA-ERDA

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    NDT Technology in Boiler & RLA-ERDA

    Uploaded by

    chandravadiyaketan1504
    26 views23 pages

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    26 views23 pages

    NDT Technology in Boiler & RLA-ERDA

    Uploaded by

    chandravadiyaketan1504

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 23

    Presentation

    on
    NDT Technology in Boiler & RLA

    Dr. U. N. Puntambekar, Asst. Director & Acting HOD


    (MIMD), ERDA, Makarpura, Vadodara
    Content

    • Introduction
    • NDT Tools & Techniques
    • RLA Methodology
    • ERDA’s Experience in RLA
    Introduction

    • Boiler Parts / Components


    • Materials
    • Standards / Codes
    Major Components

    • Steam Drum & Mud Drum


    • Economizer tubes & Headers
    • Super Heater tubes & Headers
    • Low Temp. SH tubes & Headers
    • Reheater tubes & Headers
    • Water wall
    • Attemperator Headers & nozzle
    • Main Steam line
    • Link pipes & Integral piping
    • Boiler structure & Hangers
    • Safety Valves
    • Feed water line
    Material Specifications for Heat
    Exchanging Elements

    Sr. Heat Exchanging Elements Specification


    No.

    I ECONOMISER Economiser Coils = cs SA 210 Gr. A1

    WATERWALL
    II 1. Wall Panels = CS SA 210 Gr. A1
    2. Platen assemblies =CS SA 210 Gr. A1

    SUPERHEATER
    SA 210 Gr. A1, SA 209 T1
    1. Radiant roof Panel =CS, LAS
    SA 210 Gr. A1
    2. SCW – side walls =CS
    -do-
    3. SCW – front wall panel =CS
    -do-
    III 4. SCW – Roof & rear wall panel =CS
    SA 210 Gr. A1, SA 209 T1,
    5. LTSH (Low temp.) Assembly =CS, LAS
    SA 213 T11
    SA 213 T11, SA 213 T22,
    6. Platen S.H. Vertical assembly =CS, LAS, ASS
    SA 213 TP 347 H
    7. Final S.H. Vertical assembly =LAS
    SA 213 T22, SA 213 T11
    SA 209, T1, SA 213 T11,
    REHEATER SA 213 T22, SA 213 T91
    IV SA 213 TP 304 H
    Reheater coils =LAS, ASS
    P1/Group 1Carbon Steel
    Tubes Pipes Plates Forgings Castings

    SA179 SA106GrB SA36 SA266CL1 SA216WCA


    SA192 SA333Gr1 SA515Gr55 SA350LF1 SA352LCA
    SA210GrA1 SA333Gr6 SA515Gr60 SA352LCB
    SA334Gr1 SA515Gr65
    SA334Gr6 SA516Gr55
    SA516Gr60
    SA516Gr65

    P1/Group 2 Carbon Steel

    Tubes Pipes Plates Forgings Castings

    SA210GrC SA106GrC SA515Gr70 SA105 SA216WCB


    SA516Gr70 SA266CL2SS SA216WCC
    SA299 A350LF2 SA352LCC
    P3/Group 1
    ½ Mo (C–MOLY STEELS)
    Tubes Pipes Plates Forgings Castings
    SA209T1 SA335P1 SA204GrA SA217WC1

    ½ Cr ½ Mo - P3 Group 2

    Tubes Pipes Plates Forgings Castings


    SA213T2 SA335Gr2 SA387Gr2

    P4/Group 1
    1Cr ½ Mo

    Tubes Pipes Plates Forgings Castings


    SA213T12 SA335P12 SA387Gr12 SA182F12 SA217WC6

    1¼ Cr ½ Mo
    Tubes Pipes Plates Forgings Castings
    SA213T11 SA335P11 SA387Gr11 SA182F11
    P5A/Group 1
    2¼Cr 1Mo

    Tubes Pipes Plates Forgings Castings


    SA213T22 SA335P22 SA387Gr22 SA182F22 SA217WC9

    P5B/Group 1
    5Cr ½ Mo

    Tubes Pipes Plates Forgings Castings


    SA213T5 SA335P5 SA387Gr5 SA182F5 SA217C5
    SA336Cl F5

    9Cr 1Mo

    Tubes Pipes Plates Forgings Castings


    SA213T9 SA335P9 SA182F9 SA217C9
    SA336Cl F9
    P5B/Group 2
    9Cr 1Mo ¼ V

    Tubes Pipes Plates Forgings Castings

    SA213T91 SA335P91 SA387Gr91 SA182F91


    SA199T91

    P8/Group 1
    18Cr 8Ni

    Tubes Pipes Plates Forgings Castings

    SA213TP304 SA376TP304 SA240TP304 SA182F304 SA351CF3


    SA213TP304H SA376TP304H SA240TP321 SA182F321 SA351CF8
    SA213TP316 SA376TP316 SA240TP347 SA182F347 SA351CF3M
    SA213TP321 SA376TP321 SA336F304 SA351CF8M
    SA213TP347 SA376TP347 SA336F321 SA351CF10
    SA213TP347H SA376TP347H SA336F347 SA351CF10M
    P5B/Group 2 - 9Cr 1Mo ¼ V
    Tubes Pipes Plates Forgings Castings
    SA213T91 SA335P91 SA387Gr91 SA182F91
    SA199T91

    P8/Group 1 - 18Cr 8Ni


    Tubes Pipes Plates Forgings Castings
    SA213TP304 SA376TP304 SA240TP304 SA182F304 SA351CF3
    SA213TP304H SA376TP304H SA240TP321 SA182F321 SA351CF8
    SA213TP316 SA376TP316 SA240TP347 SA182F347 SA351CF3M
    SA213TP321 SA376TP321 SA336F304 SA351CF8M
    SA213TP347 SA376TP347 SA336F321 SA351CF10
    SA213TP347H SA376TP347H SA336F347 SA351CF10M

    P8/Group 2 - 25Cr 20Ni (Type 310)

    Tubes Pipes Plates Forgings Castings


    SA213TP310H SA240TP310 SA182F310 SA351CK20
    Codes/Standards for RLA
    Applicable Codes (Acts)

    i. Indian Boiler Regulations 1950

    ii. ASME Boiler Pressure Vessel code

    iii. ASME-B 31.1 (PIPING CODE)

    iv. ASTM Standards

    v. ASNT-SNT-TC-IA Qualification and


    Certification of NDT Personnel.
    Codes/Standards for NDT
    1 ASTM E-165 Test method for Penetrant examinations
    2 ASTM E -709 Standard guide for magnetic particle
    examinations
    3 ASTM Standard test method for magnetic particle
    A-275/A275M examination of steel forgings
    4 ASTM E – 114 Standard practice for ultrasonic pulse-echo
    straight beam examination by the contract
    method.
    5 ASTM E – 587 Standard practice for ultrasonic angle-beam
    examination by contact method.
    6 ASTM E – 1158 Standard guide for material selection and
    fabrication of reference blocks for the
    pulsed longitudinal wave ultrasonic
    examination of metals and metal alloy
    production material.
    7 ASTM E – 804 Calibration of ultrasonic test system by
    extra…flat bottom hole sizes.
    8 ASTM E – 164 Standard practice for ultrasonic examination
    of welding
    Codes/Standards for NDT

    9 ASTM E – 797 Standard practice for measuring


    thickness by manual ultrasonic pulse-
    echo contact method
    10 ASTM E – 1030 Standard test method for radiographic
    examination of metal casting.
    11 ASTM E – 3032 Standard method for radiographic
    examination of weldments.
    12 ASTM E – 1351 Standard practice for production and
    evaluation of field metallographic
    replicas
    13 ASTM E – 45 Standard practice for determining
    inclusion contact of steel.
    14 ASTM E -112 Test method for determining average
    grain size.
    15 ASTM E – 139 Practice for conducting creep creep-
    rupture.
    16 ASTM E – 1444 Standard practice for magnetic particle
    examination
    NDT Tools & Techniques

    Visual & Optical Examination (VI)


    · Visual (naked eye & magnifying glass) examination (VI)
    · Remote visual inspection by fibroscopy (FOV)
    · Remote visual inspection by boroscopy (BOV)
    Dimensional Measurement (DIM)
    · Caliper & gage based measurements
    · Ultrasonics – Thickness (UT – T)
    · Eddy current thickness measurement of heat
    exchanger (condenser) tubing
    Dye Penetrant Testing (DPT)
    Magnetic Particle Inspection (MPI)
    Ultrasonics
    · Ultrasonic flaw detection (UT-F)
    MTD

    · Ultrasonic Hydrogen embitterment (UT-H)


    Radiography (RT)
    In-Situ Metallography or Replication (RPL)
    Hardness Measurement (HM)
    · Rebound hardness
    · Ultrasonic probe hardness
    In-situ Chemical Analysis (CA)
    Natural Frequency Test – for turbine blades (NFT)
    Noise & Vibration Analysis (NVA)
    · Noise measurement
    MTD

    · Vibration measurement
    · Shock pulse metering
    Ultrasonics Based Steam-Side Oxide Thickness (UT – O)
    Eddy Current Based Thickness Measurement of
    Condenser Tubes
    Eddy Current Based Detection of Near Surface Cracks in
    Turbine & Generator Blades
    RLA Methodology
    Factors Affecting the Age of Components

    DAMAGE MECHANISM
    COMPONENT
    Creep Fatigue Erosion Corrosion
    BOILER & AUXILIARIES
    1. Drums √ √
    2. Steam Headers √ √ √
    3. Water Headers √ √
    4. Steam Piping √ √ √
    5. Superheater & Reheater √ √ √ √
    6. Waterwall tubes √ √ √
    7. Ductings √ √
    8. Precipitator √ √
    9. Structures √ √

    18
    Creep
    Stress & Temperature
    Dependence of Creep

    stres Tem
    s p.
    strain

    strain
    time time
    1000
    Master rupture plot
    700 650 600 550

    Safe stress
    Stress

    100
    t
    r
    10
    15000 16000 17000 18000 19000

    LMP = T (20+log tr) Temperature

    Rupture data are more readily available for design & selection of
    material for high temperature components (boiler & turbine).
    Creep Damage Rating

    Damage Description
    Rating
    Undamaged 1 No creep damage observed.

    Isolated 2 or A Cavities are isolated on grain


    boundaries. No action required
    until next major maintenance
    outage.
    Oriented 3 or B Cavities are distributed so that
    an alignment of damaged
    boundaries normal to the
    maximum stress axis can be
    seen. Replica tests at specified
    intervals may be carried out.
    Micro-cracked 4 or C Coalescence of cavities causes
    micro-separation of some grain
    boundaries. Only limited
    service life available.
    Macro-cracked 5 or D Many grain boundary long
    cracks present. Immediate
    replacement is recommended.
    ERDA’s Experience

    • Case studies of RLA carried-out


    Thank You

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