Boiler: Boiler - (Part 4 of 4) Advanced Pressure Part Condition & Remaining Life Assessment

Course Description

This Advanced Pressure Part Condition 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, of four courses, progressively addresses the subject of boiler inspection from 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, 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 ever increasing cyclic operation.

This course will give the participants an opportunity to ask about how the laboratory analysis (both metallurgical and computer based) can be applied to the entire plant cycle including such areas as deaerator tanks or turbine blades.  Information covered can be applied to coal, oil, gas, and waste-fired boilers, industrial or utility.

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:

• Lab analysis processes that ensures thorough destructive and non-destructive examinations relative to past, present and future operating practices
• Timely and cost effective repair, modification and/or replacement decisions for aged boiler components
• Relevant case study examples of failure mechanisms and where deceptive appearances of similar failures may mislead proper corrective actions
• More complex condition assessment challenges with older boilers
• Site evaluation of issues such as welding problems, high temperature excursions, localized stress concentration that can be corrected before potential failures cripple the power plant

Course Content

The lessons for this session, Advanced Pressure Part Condition and Remaining Life Assessment, 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:

High energy piping

High temperature headers

Super-heater and re-heater tubing and oxide scale layers

Economizer tubing and headers

Water wall headers and tubing including flame spray or cladding layers

Steam and mud drums

Dissimilar metal welds, and welding in general

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 preventing repeat failures

LESSON 3 – Corrective

1. Determining when a flawed weld repair is the cause of secondary failure

LESSON 4

1. Review of Condition Assessment Concepts
2. Boiler Design Based Pressure Part PP
3. Water Chemistry Based PP
4. Fireside Thermal-Corrosive Based PP
5. Structural Metallurgical Based PP
6. Life and Integrity Assessment Methodology
7. Statistical Data Analysis, Predictions and Decisions
8. Case Study Examples (Preview)
1. Lab Site Case Study Application