World Energy Council Ministry Of Electricity Energy Egyptian Holding Company For Electricity Upper Egypt Electricit

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World Energy Council Ministry Of Electricity & Energy Egyptian Holding Company For Electricity Upper Egypt Electricity Production Company الشعبة القومية لجمهورية مصر العربية Boiler life appraisal BY ENG: IBRAHIM EL SHAHAAT

Contents The reason for evaporator life evaluation Life Evaluation by Inspection Preparations for Inspection Data necessity Inspection of high weight parts. Test tube assessment. Visual review for different parts of heater . Water quality study. Visual Inspection for aux Equipment high weight parts Inspection points of interest

1-The Purpose of evaporator life appraisal Evaluate the present state and the state of the kettle segments so as to proceed with steady and dependable kettle operation Evaluate the rest of the life for Superheater and Reheater by metallurgical assessment Evaluation of crawl life and future review plot by metallurgical investigation for water divider, economizer, Superheater and Reheater tubes Evaluation level of crawl harm for Superheater and Reheater by hardness test Evaluate the rest of the life in light of thickness Measurement for water divider, Evaluate the rest of the life in view of thickness diminishing for economizer because of low Temperature Corrosion, Evaluate the rest of the life in light of thickness diminishing for Superheater and Reheater tubes because of high Temperature Corrosion Confirm the reason for the inward scale era Evaluate the rest of the life in light of check of metal structure ,internal scale ,and so forth for test tube

2-Life Evaluation by Inspection

3-Preparations for Inspection Before examination Superheater, reheater, economizer and water divider cleaning Air warmer washing Scaffolding Removal of protection Open man gaps, assessment openings, ribs and so forth During examination Surface readiness of examination parts Surface completing the process of (granulating) of investigation parts Instrument of device of assessment Cutting tubes Welding tubes Material prerequisite New tubes Man gap pressing protection Period of review Two weeks

4-Data necessity Boiler reference information Steam temperature 0 c Maximum Steam flow Ton/hr Boiler configuration weight Kgm/cm 2 Feed water temp 0 c Reheated bay steam temperature 0 c Reheated outlet steam temperature 0 c Reheater plan pressure Kgm/cm 2 Kind of fuel Gas, Oil Functional review with heater in operation Collection of drawings and fundamental specialized information Recording of real working and useful information at various loads and conditions at MCR and Verification of the operation of the heater Collection of information significant to the warm history and intercessions ,if any made on the evaporator amid his operation life

5-Inspection of high weight parts NON Destructive test for the accompanying thing Economizer headers, loops, Piping from economizer to steam drum,. Steam drum. Heater water dividers, screen, rooftop divider, feeders, riser ,Water dividers headers. Immersion steam pipe. Essential, auxiliary super radiator. Associating channel between essential superheater and optional superheater. Reheater. Primary SH steam funnels **Inspection thing External visual examination Internal visual assessment with endoscope UT for thickness estimations by UT MT and UT on circumferential welds MT on channeling connections Metallographic investigation by plastic reproductions MT on spouts welds of the curl tubes MT on spouts welds to the shell of the gulf/outlet pipe

the base required thickness t = least required thickness. D = outside distance across of chamber. e = thickness consider for extended tube closes. P = greatest reasonable working weight. S = greatest suitable anxiety esteem at the plan temperature of the metal.

Design/Operating Information for computation of residual time in view of thickness Design data material sort or review Nominal outside breadth Designing weight Design life Deign temperature Original ostensible thickness Operating data Maximum tube metal temperature Normal working weight Original measured least thickness Metal diminishing rate Thickness estimations of water divider tubes heater

Minimum required thickness for SA178-c Minimum required thickness for various working conditions for materials SA178-c

6-Sample tube - Destructive test for the Sample tube For Water Wall ,SR and RH tubes Life analyze in light of check of metal structure, thickness, inward scale, and so on Sample tube takes as per the consequence of hardness estimation Investigation Items Visual assessment Non ruinous test Chemical examination Measurement of the tube measurement Hardness estimation Cross sectional microstructure perception Steam oxidation perception Creep break test Measurement of the internal scale thickness Information Material of Sample tube measurement

test tubes Thinning of lump zone Internal surface scale External surface scale

Optical micrograph Optical micrograph of non-bluged zones tube divider side indicating ferrite –pearlite structure with no inside deformities

Normal and crumbled microstructure ordinary microstructure ( great condition tube) Which demonstrates a run of the mill ferritic pearlitic structure weakened microstructure which demonstrates the disintegration of the pearlitic settlements

7-Visual review for different parts of kettle Burner Wind Box Hanger for riser pipe Outer packaging Skin packaging Buckstay

8-Water Quality Survey This investigation to affirm the reason for the scale era Inspection things Check of research center examination strategy for quality things Confirmation of water quality outcomes at past load operation Check of instrument condition on inspecting rack utilized for water quality control Confirmation of PH esteem and iron/copper adjust in the cycle

9-Visual Inspection for aux Equipment This review to affirm the reason for the scale era Condenser hot well. Condenser tube side Deaerator. LP-nourish water warmer. Bolster water tank. HP-nourish water radiator.

10-high weight parts Inspection points of interest Economizer headers ,loops, Piping from economizer to steam drum, Steam drum Furnace water dividers, screen, rooftop divider, feeders, riser ,Water dividers headers Saturation steam pipe Primary, auxiliary superheater Connecting channel between essential super warmer and optional superheater Reheater Main SH steam funnels

10-1 Economizer NDE For headers External visual review Internal visual assessment with endoscope Measurement of thickness by UT MT on spouts welds of the curl tubes and headers connections MT and UT on circumferential welds amongst header and tapered pieces NDE For tube External visual investigation Measurement of economizer tube and holder tube thickness with endoscope UT for thickness estimations NDE For Piping from economizer to steam drum External visual investigation for channeling, holders and backings UT for thickness estimations MT and UT on circumferential welds MT on channeling connections MT on the elbows extrados

10-2 steam drum Before the NDT reviews, the inward parts of the drum should be destroyed NDE For steam drum External visual examination Internal visual investigation UT for shell thickness estimations UT for head thickness estimations MT and UT on circumferential and longitudinal welds MT on steam drum connections (seats and frill) MT on spouts welds NDE For downcomers External visual review for channeling, holders and backings UT for thickness estimations MT and UT on circumferential welds MT on channeling connections

10-3 heater water dividers, screen, rooftop divider, Feeders and Riser NDE for heater water dividers, screen, rooftop divider External visual investigation UT for thickness estimations Metallographic examination by plastic copies Samples for ruinous test NDE for feeders and riser External visual review UT for thickness estimations NDE for headers External visual assessment Internal visual review with endoscope UT for thickness estimations MT on spouts welds of the curl tubes MT on branches welds and headers connections, including channels tubes

10-4 Saturation steam pipe NDE for each pipe External visual assessment UT for thickness estimations MT and UT on circumferential welds MT on funneling connections MT on the elbows extrados

10-5 Primary,Secondary Superheater NDE for the headers External visual assessment Internal visual examination with endoscope UT for thickness estimations UT for head thickness estimations MT on spouts welds of the loop tubes MT on spouts welds to the shell of the bay/outlet pipe MT and UT on circumferential welds amongst header and heads/funneling MT on headers connections Metallographic examination by plastic imitations NDE for Coils External visual examination UT for thickness estimations Internal visual examination with endoscope Hardness estimations Samples for dangerous examinations

10-6 Connecting channel amongst essential and Secondary Superheater, Desuperheater ATPS NDE for associating funnel External visual investigation UT for thickness estimations MT and UT on circumferential welds MT on funneling connections MT on the elbows extrados Metallographic examination by plastic reproductions NDE for desuperheater ATPS External visual review Internal visual investigation with endoscope UT for thickness estimations MT on circumferential welds Metallographic examination by plastic copies