By Electric Power Research Institute
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Additional resources for EPRI Boiler Condition Assessment Guideline 4 Edition
Header and Drum Damage: Theory and Practice: Volume 1: Information Common to All Damage Types. EPRI 2003. Report 1004313-V1. Header and Drum Damage: Theory and Practice: Volume 2: Mechanisms. EPRI: 2003. Report 1004313-V2. Impact of Operating Factors on Boiler Availability. EPRI: 2000. Report 1000560. Inherently Reliable Boiler Component Design. EPRI: 2003. Report 1004324. Life Assessment of Boiler Pressure Parts. EPRI: 2000. Report 1000311. NDE Guidelines for Fossil Power Plants. EPRI: 1997. Report TR-108450 and CD-ROM CD-108450.
The goal of Action 3 is to enable proper actions to be taken to prevent future failures due to corrosionfatigue. Execute this action in parallel with Action 4, which determines the extent of damage. Table 2-4 Action 3 – Steps for Determining Root Cause of Corrosion-Fatigue Major Root Cause Influence Actions to Confirm Influence of Excessive Stresses/Strains Restraint stresses at attachments Compare damaged locations to those typical of corrosion-fatigue Inspect susceptible locations before tube failures occur Selectively sample tubes to gauge damage accumulation Conduct finite element stress analysis to predict high-strain locations Install thermocouples and/or strain gauges to confirm high-stress locations Subcooling (cooling water stratification) in natural circulation boilers Review operating records Install thermocouples at top and bottom of boiler to monitor ΔT as function of shutdown time Install strain gauges to confirm stresses Influence of Environmental Factors 2-6 Boiler Tubing Major Root Cause Influence Poor water chemistry Actions to Confirm Review water chemistry logs and practices, with particular emphasis on pH reductions during shutdown and early startup.
Increased superheater and reheater temperatures accelerate creep damage, increase demands on attemperators, and make tubing more susceptible to erosion and corrosion. Corrosion and erosion in these and other components is also influenced by ash chemistry, fusion temperature, and abrasivity. 3% Cl) can accelerate corrosion in boilers that use overfire air for NOX control • heavily slagging coals increase the need for sootblowing, which can accelerate erosion • Powder River Basin coal tends to form more tenacious, insulating waterwall deposits and sticky convective pass deposits than eastern bituminous coal Considerations for Extending Outage Intervals Many operators have improved unit availability and decreased maintenance costs by extending the intervals between major boiler inspection and maintenance outages.
EPRI Boiler Condition Assessment Guideline 4 Edition by Electric Power Research Institute