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Janardhana, M.
- Failure analysis of water wall tubes in coal fired power plant
Abstract Views :193 |
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Authors
Affiliations
1 Engineering Officer, Materials Technology Division, Central Power Research Institute, Bangalore, IN
2 Joint Director & HOD Materials Technology Division, Central Power Research Institute, Bangalore, IN
1 Engineering Officer, Materials Technology Division, Central Power Research Institute, Bangalore, IN
2 Joint Director & HOD Materials Technology Division, Central Power Research Institute, Bangalore, IN
Source
Power Research, Vol 13, No 3 (2017), Pagination: 511-516Abstract
One of power generating utility has reported the failure of boiler water wall tubes after a service life of 10,000 hours against the design life of 30-35 years. The failure of tubes was reported in water wall tubes regions which consist of carbon steel alloy. These boiler tubes were operating under the oxidizing/ reducing atmosphere at high temperature and pressure. This paper represents the investigation the failure of water wall tubes used in a coal fired thermal power plant. The failure investigation covers visual inspection, dimensional measurement, hardness mapping, deposit flux measurement and SEM & EDX analysis of the deposited products. This paper is the case study of failure analysis of water wall tubes due to corrosion and ID deposition on the tube. The analysis reveals that the failures were due to inside corrosion and hydrogen damage attack.Keywords
Boiler water wall tube, physical observation, grade identification of alloy, dimensional & hardness measurement, corrosion deposit analysis, SEM and EDX analysis, flux deposit, ring test for hydrogen damage
- High Temperature Erosion Resistance Characteristics of Boiler Tube Materials of Thermal Power Plant
Abstract Views :171 |
PDF Views:0
Authors
Affiliations
1 Central Power Research Institute, Bangalore-560080, IN
2 Senior Research Fellow, Central Power Research Institue, Bangalore-560080, IN
3 UBDT College of Engineering, Davangere-577002, Karnataka, IN
1 Central Power Research Institute, Bangalore-560080, IN
2 Senior Research Fellow, Central Power Research Institue, Bangalore-560080, IN
3 UBDT College of Engineering, Davangere-577002, Karnataka, IN
Source
Power Research, Vol 12, No 3 (2016), Pagination: 603-612Abstract
The boiler tubes of Indian thermal power plants are exposed to severe erosive ash environment leading to continuous metal wastage and failure. The erosion resistance of the boiler tube material is affected by hardness, particle velocity, impact angle, particle size and metal temperature. The parameters affecting the erosion resistance properties are required to be evaluated in the laboratory under accelerated condition using a tunnel type erosion test rig. The present paper highlights the results of high temperature erosion of five different widely used boiler tube materials such as T11, T91, T22, carbon steel, and SS304 have been brought out in terms of their erosion resistance properties under different temperature conditions. The properties are compared with that of room temperature erosion resistance properties. The erosion resistance characteristics were studied for different velocity and impact angles around the circumference of the boiler tube. The evolution of surface roughness corresponding to different angles around the boiler tube, upon erosion, in comparison with the carbon steel tube, is presented.Keywords
Boiler Tube, Erosion, Superheater, Reheater, Surface Roughness, Impact Angle- Condition Assessment of Generator Rotor Shaft of 108 MW Hydro Plant Through Phased Array Ultrasonic Technique and Estimation of Remaining Life Through Finite Element Analysis
Abstract Views :165 |
PDF Views:0
Authors
Affiliations
1 Central Power Research Institute, Bangalore-560080, India
2 Senior Research Fellow, Central Power Research Institute, Bangalore, IN
1 Central Power Research Institute, Bangalore-560080, India
2 Senior Research Fellow, Central Power Research Institute, Bangalore, IN
Source
Power Research, Vol 12, No 3 (2016), Pagination: 613-624Abstract
The Condition Assessment of Generator rotor shaft of typical 108MW plant has been carried out involving the application of advanced Phased Array Ultrasonic Technique (PAUT)to quantify the volumetric nature of the defects in the rotor. This technique involves mapping of the entire rotor volume in different segments and layers using multiple ultrasonic sensors. The imaging of defects in the rotor shaft was carried out in four different diameter sections 558 mm, 610mm, 737 mm and 914 mm. The scanning of entire shaft geometry regions was done following different patches from top to bottom portion of the shaft by PAUT and analysis of individual scanning results for evaluation of crack size, position inside the rotor geometry and orientation. The critical defects identified by this technique with their locations and orientation inside the rotor has been presented. The stress and fatigue life of the shaft under defect free conditions have been carried out by finite element analysis using the commercial code Fe-SafeTM. The calculation of remaining life of the rotor shaft was carried out based on the principle of fracture mechanics using the code ZENCRACKTM. The results of the crack growth rate data of critical cracks close to the surface were presented.Keywords
Hydro Turbine Generator, Phased Array Ultrasonic Inspection, Stress Analysis- Study on the effects of coal-ash-slag deposition on boiler tubes in a coal-fired thermal power plant
Abstract Views :165 |
PDF Views:0
Authors
Affiliations
1 Materials Technology Division, Central Power Research Institute, Bangalore, IN
1 Materials Technology Division, Central Power Research Institute, Bangalore, IN
Source
Power Research, Vol 10, No 3 (2014), Pagination: 611-616Abstract
Coal combustion in a thermal power plant generates plenty of ashes, which gets melted at high temperature. These melted ashes, i.e. slag, gets deposited on the external surface of the boiler tube in the furnace and stick to it. This slag greatly affect the heat transfer, which leads to reduction in the efficiency of the boiler. Also, slag deposition slowly corrodes the external surface of the tube. In this paper, a typical slag deposited tube was collected from a coal fired thermal power plant and metallographic analysis was carried out on this tube and the results were compared with an unexposed tube of same material, diameter and thickness. It is concluded from the analysis that there are no significant changes in microstructure, hardness values as well as inslag compositions.Keywords
Boiler tube, slag, micro-structure, coal fired, slag indices- Conversion of Biomedical Wastes to Energy by Plasma Technologies
Abstract Views :73 |
PDF Views:0
Authors
Affiliations
1 Central Power Research Institute, Bengaluru – 560012, Karnataka, IN
1 Central Power Research Institute, Bengaluru – 560012, Karnataka, IN
Source
Power Research, Vol 17, No 2 (2021), Pagination: 75-80Abstract
The Biomedical Wastes (BMW) include variety of materials like plastics, radioactive elements, metals, infectious biomolecules, etc which are hazardous and pose potential health risk to the people when they are directly released to environment. There are many technologies for treating biomedical wastes like incineration, steam sterilisation before landfilling, etc. The plasma gasification is the state of art technology for the safe disposal of BMW and also convert them to energy. The plasma gasification operates at very high temperatures and the conversion percentage is relatively high compared to any other gasification technologies. The concept of plasma gasification for BMW and the other techno economical aspects are discussed in this paper.Keywords
Biomedical, Biomedical Waste, Plasma Gasification, Microwave, Waste to EnergyReferences
- Messerle VE, et al. Processing of biomedical wastes in plasma gasifier. Waste Management. 2018; 79(2018):791–9. https://doi.org/10.1016/j.wasman.2018.08.048 PMid:30343813
- Guidelines for Handling of Bio Medical Wastes for Utilisation, CPCB, India; 2019.
- Guidelines for handling, treatment and disposal of waste generated during treatment/diagnonsis/quarantine of COVID-19 patients, CPCB, India; 2020
- Byun Y, Cho M, Hwang S-M, Chung J. Thermal plasma gasification of municipal solid waste. Gasification for Practical Applications; 2012. p. 183–210.
- Plasma gasification commercialization [Internet]. Available from: https://en.wikipedia.org/wiki/Plasma_gasification_commercialization
- Plasma gasification. [Internet]. Available from: https://en.wikipedia.org/wiki/Plasma_gasification
- Estimation of Fly ASH Availability in a Thermal Power Plant for Cement Manufacturers
Abstract Views :70 |
PDF Views:0
Authors
Affiliations
1 Central Power Research Institute, Bengaluru – 560012, Karnataka, IN
1 Central Power Research Institute, Bengaluru – 560012, Karnataka, IN
Source
Power Research, Vol 17, No 2 (2021), Pagination: 125-131Abstract
The Indian coals are having 25 to 45% ash content and huge quantity of fly ash is being generated every day in the Indian thermal power plants. The fly ash so generated are being disposed by dry or wet mode from the power plant. The fly ash disposed in dry mode is lifted by the cement manufacturers and the fly ash disposed in wet mode is unattended. Most of the quantity of fly ash is collected in the ESPs. The particle size of fly ash collected in ESPs is finer compared to the fly ash collected in other parts of the power plant. For this reason the cement manufacturers prefer the fly ash from ESPs. The quantity of fly ash collected in the ESPs is not directly measurable on everyday basis as there are no well proven instrumental methods. Also the quantity of fly ash collected in ESPs fluctuates every day due to the varying load factor and coal quality. However, it is important to estimate the quantity of fly ash collected by ESPs on everyday basis so that the proportion of fly ash lifted by the cement manufacturers and the fly ash sent to the ash pond will be known. Presently power plants do not have a method to estimate the exact availability of fly ash and it is being theoretically calculated from the design value that the 80% of the total ash is fly ash and in that a fixed proportion (about 70% of total fly ash generated) is collected in the ESPs. However, the actual generation of fly ash would be different and this is influenced by the type of coal used, fineness of the input coal particles, boiler operating conditions, load factor, age of the power plant, etc. This uncertainty leads to disputes between cement manufacturers and the utility if there is a penalty clause in the agreement for not completely lifting the available fly ash (as theoretically calculated by the utility). In view of this it is imperative to formulate acceptable methods for determining the actual quantity of fly ash collected in the ESPs on daily basis. In the present work, a simple methodology was developed to quantity the average fly ash collected in ESPs in a 210 MWe coal fired power plant on every day basis through site measurements and routine power plant data. The amount of fly ash disposed in dry and wet mode has also been estimated through this method.Keywords
: Ash Disposal in Power Plants, Fly Ash, Cement Plants, Coal based Power Plants.References
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- Sobolev K, Vivian IF, Saha R, Wasiuddin NM, Saltibus NE. The effect of fly ash on the rheological properties of bituminous materials. Fuel. 2014; 116:471–7. https://doi.org/10.1016/j.fuel.2013.07.123
- Pereira CF, Luna Y, Querol X, Antenucci D, Vale J. Waste stabilization/solidification of an electric arc furnace dust using fly ashbased geopolymers. Fuel. 2009; 88:1185–93. https://doi.org/10.1016/j.fuel.2008.01.021 4.
- Teixeira ER, Mateus R, Cames AF, Bragana L, Branco FG. Comparative environmental life-cycle analysis of concretes using biomass and coal fly ashes as partial cement replacement material. Journal of Cleaner Production. 2016; 112(Part 4):2221–30. https://doi.org/10.1016/j.jclepro.2015.09.124
- Wu X, Fan M, Mclaughlin JF, Shen X, Tan G. A novel lowcost method of silica aerogel fabrication using fly ash and trona ore with ambient pressure drying technique. Powder Technology. 2018; 323:310–22. https://doi.org/10.1016/j.powtec.2017.10.022
- Salah N, Habib SS, Zishan HK, Mahmoud NN. Methods of making epoxy composites based on fly ash carbon nanotubes. US2017/0058096 A1; 2017.
- Maslov OD, Tserenpil S, Norov N, Gustova MV, Filippov MF, Belov AG, et al. Uranium recovery from coal ash dumps of Mongolia. Solid Fuel Chemistry. 2010; 44:433–8. https://doi.org/10.3103/S0361521910060133
- Kumar M, Bajpai S, Dewangan UK, Kumar R. Suitability of leaching test methods for fly ash and slag: a review. J. Journal of Radiation Research and Applied Sciences. 2015; 8:523–37. https://doi.org/10.1016/j.jrras.2015.06.003