MARCH 2008 FEED BACK: 2 PROJECT : JINDAL STAINLESS LTD , 125 MW UNIT-1 PROBLEM : REPEATED WATER WALL TUBE FAILURE PROBLEM: INTRODUCTION: Tindal stainless Itd , 125 MW Unit-1 was first coal fired on 16.12.07. Initially unit was being operated at approximately 60-70MW according to availability ESP passes and Mills. THE PROBLEM Repeated tube failures were occurred in the same tube for three times OBSERVATION, ACTION DETAILS AND ANALYSIS: First water wall tube failure was observed on 06.02.2008 in corner-3 (around 1.5 M above top most burner) at about 30mtr elevation in the fifth tube of rear waterwall counting from right and found it is fish mouth opening. After repair, unit was again lighted up on 08.02.08. On 12.02.08 at 8.12 am, a similar failure was noticed for the 2" time in the same fifth tube at around 200 mm below the earlier failure occurred on 06.02.08. THE FOLLOWING ACTIONS WERE TAKEN: The failed tube was cut in corner-3. A spool piece was also cut at the bottom (straight portion) at an elevation of 8.5 M . Compressed air was blown from the top of the failed tube cut opening and free airMARCH 2008 TS TIDINGS flow was observed from upper side of the bottom opening near ring header. Ring header also was checked for any foreign materials by cutting the hand hole and inspection thro' boroscope. Nothing was found. After ensuring no choke , this failure was repaired with new tubes of 3.5 meter and 1.8 meter up to site weld joint above and below the point of failure. The failed tube sample along with sample pieces cut from above and below the failed tube were sent to BHEL/Trichy for laboratory analysis. Thickness measurements for both the failed tubes as well as the adjacent tubes were ‘done to decide replacement requirement. Hydraulic test was conducted at working pressure. Unit was restarted on 23.02.08. and Tube failure(fish mouth opening) in the same fifth tube was noticed again for the 3° time at about 00.30 hrs on 27.02.08 in the same month. This time the failure is just below the rear arch. After ensuring no choke in the tube and completion of thickness survey the failure was repaired. Additionally Six nos of thermocouples were installed in corner-3 for observation of water wall metal temperature. Unit was put back into service on 02.03.08. WW tube failure occurred again on 04.03.08 at 08.20 am in 7th tube of corner -3 burner panel counting from rear to RHS. Unit was operating at 90 MW and HPH 5 Only was in service since 03.03.08 Checks were carried out similar way like third failure. ANALYSIS OF FAILURE Since no choking was observed and tubes failures were repeatedly occurring other possible causes were studied.23 MARCH 2008 TS TIDINGS It was observed that all these failures were taking place once the unit was run continuously for 10 to 12 hrs around 90 to 95 MW with boiler pressure120 kg/cm? Failures are being fish mouth opening and primary failure ,the cause for failure is overheating. Hence starvation of flow was also suspected. So data were collected from DCS history and trend curves for analysis. It was found the that unit has been operated with low drum level (below trip levels), which could have caused overheating of water wall tubes and caused tube failure . Refer data below: JSL UNIT-1 OPERATION DATA BEFORE 4TH WW TUBE FAILUIRE ON 04.03.08 TiME [LOAD [DRUM PR |FWFLOW [ORUMLEVEL WW TUBE METAL TEMP HRIMIN MW [KSCG [TPH ‘wi NEAR THE AFFECTED ZONE IN CORNER 3 TUBE NO 5B/7B /7T 7.42 [805] 101.44 264 =19.94| '303/ 296/ 273 7.43 | 81.7] 102.45] 267 =37.22| 304/ 296/ 273 7.45 | 81.0 102.00) 236) 204! '304/ 296/ 273 7.50_| 820 102.001. “187 “304/ 295/273 8.00 | 83.0 98.00) 2ail 317 "366/ 356/345 8.06 | 71.0 87.00) 3 -327] 6771 576/ 536 eit 43.00) 274) -158 286/ 304/ 198 Besides drum level protections were also found not in service. Also no leakages have occurred in the fifth tube later there was a possibility of choke getting cleared during the third failure. CORRECTIVE MEASURES. Drum level transmitters were checked in cold condition and found matching with Electronic Water Level Indicator (EWLTI) and Direct Water Level Gauge (DWLG). Steam and water side DWLG/ EWLI/ Level Transmitter (LT) tapping points lengths were checked and found as per drawingMARCH 2008 TS TIDINGS Sixteen nos of pad type thermocouples were installed in corner 3 (10 nos) and corner 2 (6 nos) water wall tubes for observation and monitoring of water wall metal temperature. Drum was opened and inspected from both ends. The vortex breakers were found intact Drum level control was put on auto on single element as well as three elements. The operation engineers were advised to be more vigilant to monitor the water wall metal temperature especially during transient conditions like mill / oll gun introduction/ changeovers. Rated parameters like drum/SH pressures were ensured. Drum level protections were kept in service. Unit was lighted up on 08.03.08 around 00.30 hrs after completion of necessary repair of 4" failure and other works as mentioned above. RESULT With above measures, the unit has been operating continuously without any abnormal rise of water wall metal temperature till date. Enclosures 1. Attachment-1 showing location details of all the above four failures. 2. Attachment -2 Tube sample location details. 3. Failed tube Photo and Summary of report 4. Drum level trendMARCH 2008 TS TIDINGS ATTACHMENT - 1 USL UNIT-1 WW TUBE FAILURE LOC ATION DETAILS. ‘THE FIST THREE WW FAILURES WERE IN STH TUBE OF CORNER 3 BURNER PANEL ‘THE 4TH WW FAILURE IS IN 7TH TUBE OF CORNER 3 BURNER PANEL COUNTING FROM REAR TO RIGHT ‘tn ube of burner panel corer 3 counting _ from rear to RHS. a Me : _-v AREA FAILED ON 27 2.08- 00:30 HRS (Gre tare {ew snare ‘AREA FAILED ON 04.03.08 Ss AREA FAILED ON 62.08, AREA FAILED ON 12.2.08 (2nd faire) BURNER PANEL ON 12.2.08 | “Sa REMOVED UPTO EW ABOVEMARCH 2008 TS TIDINGS ATACHMENT 2 SL UNIT-1 WW TUBE SAMPLE LOCATION DETAILS {,UNFAILED SAMPLE T 2. FAILED SAMPLE F FAILED ON 6.2.08 ". S.UNFAILED SAMPLE 61 4.UNFAILED SAMPLE B227 MARCH 2008 TS TIDINGS PHOTO OF FAILED TUBE SUMMARY OF TUBE SAMPLE REPORT OF BHEL/TRICHY 1, The chemical composition of the tube samples meet the requirements of SA 210 Grade C. 2. The failure of the water wall tube is attributed to short tem overheating to above ACI but below AC3 temperature of the material of the steel. 3. Tube Nos T and B1 (unfailed samples) also show overheating to below ACI as seen from the bulging and microstructures observed.ae 28: WATER WALLTUBE TEMP ae ie Waal as SONIOLL SL28: WATER WALLTUBE TEMP eee SONIOLIL SL