Professional Documents
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Metallurgical analysis
Failure analysis Health/ Condition Assessment Residual Life Assessment Indegenisation / Material Development
Components
Boiler tubes Turbine components High Energy Piping CHP Components Grinding elements Gas Turbine Components
Failure Mechanisms
(Water Touched Tubes)
Corrosion Fatigue Flyash Erosion Hydrogen Damage Acid Phosphate corrosion Caustic Gouging Fireside Corrosion Thermal Fatigue Erosion Corrosion Sootblower Erosion Short Term Overheating Low Temperature Creep Chemical Cleaning Damage Fatigue Pitting Coal Particle Erosion Falling Slag Damage Acid Dew Point Corrosion
Failure Mechanisms
(Steam Touched Tubes)
Long Term Overheating / Creep Fire Side Corrosion Dissimilar Metal Weld Short Term Overheating Stress Corrosion Cracking SH/RH Sootblower Erosion Fatigue Rubbing Tubes / Fretting Pitting Graphitisation SH /RH Chemical Cleaning
Visual examination of damaged parts is the first and most critical step in failure investigation
Singarauli STPS
Boiler No.3 Date of Failure: 05/04/2004 Zone: Economiser Lower Bank Location: Coil No.02 Material: SA210 A1 R&D Ref: 2210
Kahalgaon STPS
Boiler No.2 Date of Failure: 28/03/2004 Zone: Convection Pass Wall (RHS) Location: Front Tube-01 (from RHS) Material: C20 R&D Ref: 2209
Ramagundam STPS
Boiler No.1 Date of Failure: 01/03/2004 Zone: Economiser LHS wall Location: Bank no.03 (from rear) Material: SA210 A1 R&D Ref: 2198
Corrosion Fatigue
Ramagundam STPS
Boiler No.2 Date of Failure: 27/02/2004 Zone: Reheater Location: Bank-05, Coil-22, Tube-07 Material: SA213 T22 R&D Ref: 2199
Korba STPS
Boiler No.1 Date of Failure: 09/01/2004 Zone: Reheater Location: Panel-31, 3rd Bend, 2nd Bunch Material: SA213 T11 R&D Ref: 2132
Pinhole on weld
Vindhyachal #8
S-Panel Water Wall Tube Failure Dated 06/12/2003 Report No R&D/MET/2073
2073
Origin of Leak
Origin of Leak
NCPP Dadri #2
S-Panel Water Wall Tube Failure Dated 05/11/2003 Report No. R&D/MET/R-2118
TANDA Unit #2
Hydrogen Damage Failure in Water Wall
Thermal Fatigue
Hydrogen Damage