Boiler: Boiler - (Part 3 of 4) Pressure Part Failure Analysis & Prevention

Course Description

This Pressure Part Failure course is designed to benefit personnel responsible for inspecting and maintaining the boiler and its auxiliaries.  Emphasis is on common points for all boiler inspections.

The Boiler Inspection series progressively addresses the subject of boiler inspection starting with the fundamentals of inspecting thick-wall (headers/drums) and thin-wall (tubes) pressure parts as well as those sub-components closely associated with reliable operation.

In the advanced assessment phase of this series, the lessons will take stress analysis to a higher level where component life and integrity assessment can be projected beyond the traditional 30-year period, factoring in the risks associated with cyclic operation.

Duration

2 Days

Target Audience

Supervisors

Mechanical Maintenance

Prerequisites

Instruction is given in English; therefore, a reasonable ability to read and understand spoken English is required

Attended previous Boiler Inspection Fundamentals and NDE Condition Assessment course or previous knowledge in power plant inspection and maintenance

Class Size

Maximum number of students: 18

Learning Objectives

This course will provide basic knowledge on the following:

Identifying both failure mechanism and/or component-based assessment techniques to be applied to any failure

Applying timely and cost effective repair, modification and/or replacement decisions for aged boiler components

Sharing in the process of relevant case study examples of failure mechanisms and learn where deceptive appearances of similar failures may mislead proper corrective actions

Addressing the more complex condition assessment challenges with older boilers

Recognizing when site evaluation of issues such as welding problems, high temperature excursions or localized stress concentration can be corrected before potential failures cripple the power plant

Course Content

Lessons for this session apply a laboratory focus on the following systems and equipment.  Predictive, preventative and corrective boiler and auxiliaries maintenance tasks are addressed from the perspective of pre-outage, outage and post-outage periods:

INTRODUCTION

1. Instructor Background
2. Participant Background
3. Course Schedule

LESSON 1 - Predictive

1. Determining remaining life expectancy using laboratory analysis and computer-based models

LESSON 2 – Preventative

1. Identifying the root cause of tube failures to prevent repeat failures

LESSON 3 – Corrective

1. Determining when flawed weld repair is cause of secondary failure
2. Implementing proper plan to eliminate future failures

LESSON 4

1. High energy piping
2. High temperature headers
3. Super-heater and re-heater tubing and their oxide scale layers
4. Economizer tubing and headers
5. Water wall headers/tubing including flame spray or cladding layers
6. Steam and mud drums
7. Dissimilar metal welds, and welding in general
8. Super-heater and re-heater de-super heaters

This course will give the participants an opportunity to ask how laboratory analyses (both metallurgical and computer based) can be applied to the entire plant cycle, including components such as deaerator tanks or turbine blades.