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Research Papers: Operations, Applications & Components

Research and Application of Risk Assessment Methodology for Power Station Boiler Superheaters

[+] Author and Article Information
Fujun Liu

 Zhejiang Provincial Special Equipment Inspection and Research Institute, No. 211 Kaixuan Road, Hangzhou, Zhejiang 310020, Chinalfj_dq@126.com

Shuai Kong, Zhangwei Ling, Qiang Li, Yueqiang Qian, Mulin Zheng

 Zhejiang Provincial Special Equipment Inspection and Research Institute, No. 211 Kaixuan Road, Hangzhou, Zhejiang 310020, China

J. Pressure Vessel Technol 133(4), 041602 (May 18, 2011) (10 pages) doi:10.1115/1.4002861 History: Received April 16, 2010; Revised October 16, 2010; Published May 18, 2011; Online May 18, 2011

Risk-based inspection (RBI) has been applied to good effect in relation to pieces of equipment and pipelines in the petrochemical industry worldwide, but to the best of our knowledge application of RBI to power station boilers has not hitherto been reported. The tubes of the four key components, namely, the economizer, the water-cooling wall, the superheater, and the reheater, are prone to blast due to direct fire heating. Such a blast always causes unplanned shutdown and has severe safety implications. Based on the “API 581-2000” code (Risk-Based Inspection Base Resource), the failure mechanisms of power station boilers have been studied, and the high-temperature smoke erosion factor and high-temperature creep factor have been calculated. Then, considering specific situations in China, such as material quality and extended service, a failure modification factor based on remaining life has been proposed. Finally, two risk assessment projects have been carried out; after delineating the risk levels of the tubes, appropriate management suggestions have been proposed. The obtained data should provide some technical support for the application of RBI to power station boilers.

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Copyright © 2011 by American Society of Mechanical Engineers
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References

Figures

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Figure 6

The risk matrix of project 1

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Figure 1

Pictures of an accident: (a) creep split and (b) chain split

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Figure 2

The relationship of the probability of failure considering remaining life and the failure modification factor based on remaining life versus the remaining life Lremain

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Figure 3

The layout diagram of the superheater tube with 81×4 W tubes: (a) tube array and (b) No. 1 tube

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Figure 4

The finite element model of superheater tubes: (a) integrated model and (b) localized model

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Figure 5

The velocity field of single-row and 16-row models with the incoming smoke at orientations of 0 deg, 30 deg, and 45 deg. ((a) and (b)) The single-row and 16-row models with 0 deg orientation; ((c) and (d)) the single-row and 16-row models with 30 deg orientation; ((e) and (f)) the single-row and 16-row models with 45 deg orientation.

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Figure 7

The layout diagram of the superheater tube with 46×7 W tubes: (a) tube array and (b) No. 1 tube

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Figure 8

The risk matrix of project 2

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