Case Study:

Condition and Life Assessment of Boiler

at a Power Station
Overview
Quest Integrity Group performed a complete condition and life assessment of a boiler at a thermal power plant in
Southeast Asia. The boiler examined was a Riley Stoker design, constructed by Mitsui Engineering in 1982. The boiler forms part of a 300MW unit capable of being fueled by fuel oil or natural gas. The unit had completed approximately 120,000 hours of operation at the time of this project.
The objective of this project was to assess the general and metallurgical condition and remaining life of the superheater tubes, piping and pressure vessels of the boiler. The scope of work included the following:

Ultrasonic thickness
measurement (USTM)
Magnetic particle inspection (MPI)
In-situ metallographic
examination
In-situ hardness testing

Fiberscope inspection
Laboratory examination
and documentation
Evaluation and reporting

A summary of the sections of the boiler that were tested and

the tests performed are presented in the table below:

Boiler Section

Test(s) Performed

High Temperature Reheater

Tubes

USTM

High Temperature Superheater

Tubes

USTM

Intermediate Temperature Superheater Tubes

USTM

Feedwater Pipe

USTM and MPI

Boiler Steam Drum

USTM and MPI

Deaerator and Storage Tank

USTM

Boiler Blowdown Vessel

USTM and MPI

Boiler Blowdown Flash Vessel

USTM

HP Clean Drain Collection

Vessel

USTM and MPI

Main Steam Pipe

USTM, MPI, surface metallography and hardness test

Hot and Cold Reheater Pipe

USTM, MPI, surface metallography and hardness test

Superheater Cross-over Pipe

Fiberscopic inspection

The sectional drawing of the boiler, indicating the various

examined locations, is shown above.

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Case Study:
Condition and Life Assessment of Boiler
at a Power Station
Results
The results of this assessment indicated that the boiler and steam pipework were in generally good condition, and
should be capable of operation well beyond their design life. There were indications that sections of the high temperature superheater have been operated at temperatures in excess of the design values. Consequently, a greater than
expected fraction of the life of associated components has been expended.
In the case of the final (high temperature) superheater outlet header, it was recommended that accelerated postexposure creep tests be considered. This would involve removal of small samples from these critical pressure parts,
preferably by a core drilling method. The data derived from such tests would enable the remaining life of these components to be predicted with an otherwise unachievably high level of confidence. The results would allow optimum capital
replacement scheduling.
Evidence was found that flow assisted corrosion (FAC) had taken place within the deaerator and feedwater pipework
leading to the boiler feed pumps. The water temperature between the deaerator and HP heaters was such that magnetite solubility could increase to a peak level rapidly with a small drop in pH. Consequently, the feedwater pipework in
this area was considered to be at a higher risk of failure due to FAC. Failures in other parts of the world have led to
several fatalities. It was therefore recommended that consideration be given to a more complete and detailed survey of
this area at a later date.
A significant amount of oil-ash fouling was discovered on the external surfaces of the boiler tubes in the (front) hightemperature section of the boiler. These deposits were found to have a composition that is associated with severe corrosion of Cr-50 material as used for tube support lugs. The latter were extensively damaged, particularly in the area of
the intermediate and high temperature superheater. It was recommended that these supports be repaired to prevent
consequential mechanical damage to nearby areas due to fatigue.
The deposits were found to be fused to the external surfaces of the intermediate and high temperature superheater
and were difficult to remove. Other plants used fuel additives that can reduce or remove these deposits within a relatively short period of operation (2000 hours to 4000 hours), and thereby improve heat transfer characteristics and overall efficiency. It was suggested that consideration be given to trials of such additives on Units 1 and 2 if the boilers are
to be fueled by oil for a significant part of their future operational campaign.

Quest Integrity Group

Quest Integrity Group is focused on asset integrity and reliability management solutions for our clients. Our solutions are comprised
of technology-enabled advanced inspection and engineering assessment services and products that help companies in the refining
and chemical, pipeline, syngas and power industries increase profitability, reduce operational and safety risks and improve operational planning.
Quest Integrity Group is built on a foundation of leading edge science and technology that has innovated and shaped industries for
nearly forty years. As a dynamic business with a global presence, we are responsive to your needs and focused on empowering
your operating and maintenance decisions.

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