Professional Documents
Culture Documents
3.1.1 How to carry out maintenance of aged thermal power plants (increasing longevity)
How to carry out maintenance of aged thermal power plants leads to studies and judgments being carried out
from comprehensive viewpoints such as a source program into the future including nuclear, hydro, etc.,
positioning and role in terms of a power generation program, outlook regarding the renovation costs required to
upkeep function and soundness, trends in fuel costs according to power generation efficiency and fuel class,
outlook for the introduction of alternative sources, trends in technological development, etc. to define the direction.
However, the current course of action is broadly divided into the following two items (Fig. 3.1.1):
(1) Maintaining operation through the renewal of deteriorated plant equipment (increasing longevity)
This is a direct extension of matters that we have implemented conventionally as measures against age
deterioration, and plans continuance of operation (increasing longevity) for about 60 years (within the
range where substantial renovation of civil and construction equipment such as piles and foundations is
not required).
(2) Maintaining operation through repowering, replacement, etc. (increasing longevity)
(3) Planning the continuance of operation (increasing longevity) through repowering, replacement, etc.
allowing an increase in the scale of output, improvement of power generation efficiency, improvement
of operational function, environmental betterment, etc. is to be carried out in conjunction with the
renewal of deteriorated plants (The target is mainly small- to medium-capacity plants).
3.1.2 Maintaining operation through the renewal of deteriorated plant equipment (increasing
longevity)
The actual service life of plant equipment differs from its nominal design life and it is significantly dependent
on good or poor operation and maintenance. With respect to thermal power plants, for the purpose of keeping
their function and performance at an established level, the scope of inspection, method and frequency are defined
on an equipment-by-equipment basis as a standard, and patrols, routine checks, periodic inspections, and service
and maintenance (repair, replacement, etc.) are performed according to such standard.
Further, as to aged thermal power plants, in addition to these items, precise inspection for the pressure part of
the boiler, turbine rotor, casing, major valves and rotor power generator, remaining life assessment, renewal of
deteriorated equipment and portions, addition of equipment function to respond to demand-supply operation, and
strengthening and enhancement of durability are planned simultaneously.
[Measures to
[Background] [Background] [Needs] increase longevity] [Destination]
Maintaining operation
Developing Long-term operation increasing longevity through the renewal of
program program (prolonging life) deteriorated equipment
Power generation [Measures to Stable supply
increase longevity] Cost reduction
Repowering
Replacement
(addition)
Fig. 3.1.1: How to carry out the maintenance of aged thermal power plant (increasing longevity)
142
Maintenance of [Example]
aged thermal power Operation control • Monitoring of life consumption of high-
Operation temperature thick part of boiler and turbine
plant Monitoring of • Diagnosis of boiler combustion
operation status • Monitoring of vibration of large rotating
machine
Enhancement of operation control • Trip test of safety device
Routine inspection/test
and supervisory function • Routine replacement of auxiliary machine
Reduction of load on equipment • Vibration of auxiliary rotating machine
Early detection of problems Patrol • Operation status of auxiliary machine
• Opening of control valve
Daily simplified
maintenance
For this reason, even if the plant reaches its nominal design life, there is still considerable practical operation
life of a major plant, and, as to the reliability of the entire plant as well, it is understood from long-term experience
of operation and maintenance that continuance of operation (increasing longevity) may be possible at relatively
low cost.
Basically, although this is a direct extension of matters that we have implemented conventionally as measures
against aged deterioration, for the purpose of maintaining stable operation while securing the economics, it is
necessary to push ahead with understanding and preserving (recovering from deterioration) the function,
performance and soundness of plant equipment more efficiently than conventionally, and it is requested that plant
diagnosis (deterioration diagnosis, remaining life assessment) technology, renovation technology, trouble
information, etc. be used to further push ahead with critical classified renovation according to the operation period
and operational method. [Fig. 3.1.2]
From here, we introduce developments in operation and maintenance of aged thermal power plants in the past,
renewal conditions of aged machines, devices and portions, inspection technology and remaining life assessment
technology, examples of large renovation for maintaining operation (increasing longevity), acceleration of the
time necessary for periodic inspection that tends to become longer with aging, a work program support system for
critical classified renovation, status of efforts to cope with the increase in longevity of aged thermal power plants
in U.S.A., etc.
3.1.2.1 Operation & maintenance status of aged thermal power plants (from the 50s to the early 60s of
the Showa period)
Aged thermal power plants were originally designed to operate continuously (operation to cover the base load).
1992
(September) 50 Showa period = 1975
10 thousand kW
1970 (September)
Time
Fig. 3.1.2.1-1: How electricity is used in a day (example)
143
Equalizing pool type Table 3.1.2.1-1: Precise inspection (representative
Pumped-storage
Water reservoir-type hydro
hydroelectric power example)
Plant Portion to be Inspection method
inspected
Pumped-storage Oil Steam Rotor Visual inspection with bore scope
power turbine Ultrasonic testing
Magnetic particle testing
Moving blade Ultrasonic testing
Measurement of lifting amount of
LNG, LPG and
stud part
other gases
Casing Structure examination of
Coal representative point (macro)
Boiler Superheater Ultrasonic testing (weld point)
Nuclear and reheater Tube removal examination from a
power tube representative point
Drum Radiographic test
Main steam
Run-off river-type hydro pipe Ultrasonic testing
Reheat steam
(Time) pipe
Generator Rotor Visual inspection with bore scope
Fig. 3.1.2.1-2 How electricity is used in a day Ultrasonic testing
(representative example) Magnetic particle testing
Transformer Main body Oil leak test
Dissolved gas analysis
Electric Rotor Liquid penetrant detection test
motor Insulation diagnosis
Base load operation was carried out at the initial stage of construction. However, because of subsequent changes
in the demand-supply structure, that is to say, an increase in demand (maximum electricity demand), a widening
of the gap in demand-supply between day and night, and an increase of the segment share of nuclear power
generation, base load operation handed over its role to nuclear power and large-capacity thermal machines. As a
result, the operation pattern has changed to the operation of a middle-sized thermal power plant positively bearing
adjustment between demand and supply, i.e., the operation pattern under which load change, reduction of
minimum load, frequent start up and shut down, etc. are performed.
144
Table 3.1.2.1-3: Examples of improvement in medium-capacity machines
[Improvement in durability of plant]
• Improvement of suspended superheater of boiler (Fig. 3.1.2.1-3)
• Improvement of shape of disk base part of steam turbine rotor (Fig. 3.1.2.1-4)
• Reduction in stress of steam turbine casing (improvement of shape) (Fig. 3.1.2.1-5)
• Improvement of spray at exhaust chamber of steam turbine (Fig. 3.1.2.1-6)
[Expansion of operation controllability and supervisory function]
Improvement and enhancement of supervisory function for those
that have high frequency of control at start up and shut down
that have simultaneous operation
that have difficulty in adjustment
• Making the control of the boiler burner remote or automatic
• Making the control of the drain valve and auxiliary machines of the boiler and turbine remote
• Automatic start up of turbine from central operating panel (TSC)
• Making the oil temperature control on the turbine bearing automated from a central operating panel
• Making the injection of feed water and chemicals automatic from a central operating panel
• Installation of furnace gas thermometer
• Installation of turbine bearing a metal thermometer
For the purposes of securing the reliability and performing strict demand supply adjustment operation such as
DSS (daily start up and shut down), etc. of the plant equipment designed originally based on the premise of base
load operation given that aging progresses, we have basically planned :
• An operation pattern that will contribute to demand-supply adjustment sufficiently and where start-up and shut-
down loss is minimized
• Securing of strength and allowance of a plant sufficient to cope with thermal stress, repeated stress arising from
start up, shut down, load change, etc. and creep damage associated with secular use
• Improvement of operability and enrichment of supervisory function so that the operator can cope with the
situation within limited time and simultaneous operation
• Early detection and handling when there is an abnormal condition in the plant
• Establishment of optimum operation pattern through operation testing
• Precise inspection and remaining life assessment for plants whose cumulative operation time has exceeded
100,000 hours (Table 3.1.2.1-1, 2)
• Improvement of plant durability (Table 3.1.2.1-3, 4)
• Improvement of operability and controllability, enhancement of monitoring function (Table 3.1.2.1-3, 4)
Disk
Curvature Curvature
Processed point
radius radius
Big
Big
Small
Fig. 3.1.2.1-3: Improvement of suspended superheater Fig. 3.1.2.1-4: Improvement of shape of disk base part
of boiler of steam turbine rotor
Casing
Diaphragm
Nozzle
Packing casing cone
Final-stage blade
Fig. 3.1.2.1-5: Reduction in stress of steam turbine Fig.3.1.2.1-6: Improvement of spray at exhaust chamber
casing (improvement of the shape of casing) of steam turbine
145
Table 3.1.2.2-1: Examples of improvement in large- [Before improvement] [After improvement]
capacity machines (Constant-pressure supercritical once-
through system)
[Improvement of plant durability]
• Improvement of superheater header part of boiler (Fig. 9)
• Processing of membrane-end part of boiler (Fig. 10)
• Improvement of structure of surrounding wall tie-bar of boiler (Fig.
11)
• Improvement of passing-through part at boiler tube wall (Fig. 12)
• Improvement of support system for main piping of boiler (Fig. 13)
• Reinforcement of start system valve of boiler (Fig. 14)
• Reinforcement of feed water control valve of boiler (Fig. 15)
[Improvement of controllability and enhancement of supervisory .
function] (a) Bringing header tube nozzle to flexible structure
Improvement of controllability to plan the improvement of
controllability at start up/shut down and when the load changes • Corner R processing
• Digitization of APC control
• Automation of boiler automatic burner
• Expansion of automatic start-up control range of turbine
• Improvement of controllability on the drain level of feed water
heater
Nozzle
• Bringing auxiliaries to group control (master)
• Addition of life supervisory function for thick pressure-resistant part (b) Corner R processing of header tube nozzle part
of boiler
• Automation, enhancement of supervisory function and man-machine
Fig. 3.1.2.2-1 Improvement of superheater header
communication part of boiler
Membrane bar Membrane bar
Water-cooling
Tie-bar clip wall tube
Tie-bar Tie-bar
Old toe
Wall
Tube leg
Torque bracket New toe
A-part
Improvement of structure of tube leg at wall passing-through part
Fig. 3.1.2.2-4: Improvement of passing-through
part at boiler tube wall
Shear lag
146
The following are the reasons for renewal according to the equipment of each plant, renewal rate and equipment
whose renewal due to “deterioration and damage” exceeds 20% extracted from such report:
(1) Boiler plant related (Fig. 3.1.2.2-8)
1 Furnace tube
Renewal rate: About 36%
Renewal time: From less than 40,000 hours to 200,000 hours
The renewal peak falls within the range of 100,000 to 200,000 hours.
2 Superheater 1st
Renewal rate: About 25%
Renewal time: From less than 40,000 hours to 200,000 hours or more
The renewal peak falls within the range of 120,000 to 140,000 hours.
Reason for renewal: As many renewals have been performed after 120,000 hours, conceivable reasons for
renewal are creep damage, external high-temperature corrosion and ash erosion.
3 Superheater 2nd to 4th
Renewal rate: 2nd About 56%
3rd About 66%
4th About 70%
Renewal time: 2nd: From less than 40,000 hours to 200,000 hours or more
The renewal peak falls within the range of 100,000 to 120,000 hours.
3rd and 4th: From 60,000 hours to 160,000 hours
The renewal peak falls within the range of 80,000 to 100,000 hours.
Reasons for renewal: As there are many renewals for those whose main steam temperature is 550°C or
more, for those for WSS (weekly start up and shut down) operation and for heavy
oil-fired ones, conceivable reasons for renewal are creep damage and high-
temperature corrosion.
4 Superheater weld joint with dissimilar materials
Renewal rate: About 47%
Renewal time: From less than 40,000 hours to 180,000 hours.
The renewal peak falls within the range of 80,000 hours to 160,000 hours.
Reason for renewal: As there are many renewals for those whose main steam temperature is high and for
heavy oil-fired ones, conceivable reasons for renewal are creep damage, thermal
stress fatigue and high-temperature corrosion.
147
The renewal peak falls within the range of 80,000 hours to 120,000 hours.
Reasons for renewal: From the fact that there are many renewals of those whose steam pressure is high for
both the 1st and 2nd reheater, and in the case of the 1st reheater, there are many
renewals of those for DSS operation, a conceivable reason for renewal is thermal
stress fatigue.
7 Valves
Renewal time: Form less than 40,000 hours to 180,000 hours
The renewal peak falls within the range of 100,000 hours to 120,000 hours.
Reasons for renewal: From the fact that there are many renewals of those with many start ups, a
conceivable reason for renewal is seat leak.
8 Electrostatic precipitator (discharge electrode, collecting plate, hammering device, charging equipment
(P/P))
Renewal rate: Discharge electrode About 57%
148
Collecting plate: About 46% Renewal time: From less than 40,000 hours to 180,000
Hammering device: About 39% hours or more
Charging equipment (P/P) About 29% The renewal peak falls within the range of 100,000
hours to 120,000 hours.
9 Duct extension
Degradation Damage Performance
damage prevention Regulation upgrading
High-pressure external casing
Medium-pressure external casing
Low-pressure external casing
High-pressure internal casing
Medium-pressure internal casing
Low-pressure internal casing
High-pressure external casing high-temperature bolt
Medium-pressure external casing high-temperature bolt
High-pressure internal casing high-temperature bolt
Medium-pressure internal casing high-temperature bolt
High-pressure rotor
Medium-pressure rotor
Low-pressure rotor
High-pressure-stage rotating blade
Medium-pressure-stage rotating blade
Low-pressure-stage rotating blade
High-pressure-stage stationary blade
Medium-pressure-stage stationary blade
Low-pressure-stage stationary blade
Main steam stop valve valve box
Control valve valve box
Reheat steam stop valve valve box
Intercept valve valve box
Names of renewed equipments
151
Degradation Damage Performance
damage prevention Regulation upgrading
Replacement of generator stator
Rewinding of generator stator
Replacement of generator rotor
Rewinding of generator rotor
Generator hydrogen gas cooler
Generator stator cooling system
Generator hydrogen gas shaft seal oil system
Generator lead bushing
Exciter
Generator for exciter
Motor for exciter
Rectifier for exciter
Exciter AVR
Cooling system for exciter
Isolated-phase bus support bushing
Isolated-phase bus wall passing-through bushing
Outdoor high-voltage motor
Rewinding of outdoor high-voltage motor stator coil
Outdoor high-voltage motor rotor
Names of renewed equipments
Fig. 3.1.2.2-10 Reasons for renewal and renewal rate by electric plant equipment
152
Degradation Damage Performance
damage prevention Regulation upgrading
Unit interlock
Auxiliary machine interlock
Combustion control unit
Feed water control unit
Steam temperature control unit
Burner control unit
Governor control unit
Tb monitor vibration diagnosis system
TB monitor shaft vibration meter
Tb monitor shaft eccentricity meter
Tb monitor shaft position meter
Tb monitor revolution meter
Tb monitor difference expansion meter
Tb monitor cam position meter
Unit computer
Data logger computer
Environmental data-processing computer
Fuel control computer
Water quality control analyzer
Fuel analyzer
Exhaust gas NOx analyzer
Names of renewed equipments
Fig. 3.1.2.2-11 Reasons for renewal and renewal rate by instrumentation control plant
153
due to deterioration of the signal conversion unit, indication mechanism, etc. of each
controller and increasing difficulty in procuring parts because of discontinuance of
production of similar equipment.
For the renewal due to performance upgrading, many renewals were performed due
to nationalization of imported products or due to change from an air or mechanical
system to an electric or digital type, and it is conceivable that many renewals had the
objective of conversion to APC or full automation, etc.
2 Turbine monitor
Renewal rate: Vibration diagnosis system About 57%
Shaft vibration meter About 67%
Shaft eccentricity meter About 65%
Shaft position meter About 57%
Revolution meter About 49%
Difference expansion meter About 60%
Cam position meter About 56%
Renewal timing: Renewal of any equipment falls within the range of 40,000 hours to 180,000 hours.
Reasons for renewal: There are many renewals due to degradation damage and damage prevention.
Conceivable reasons for renewal are failure attributable to the deterioration of each
sensor, conversion amplifier, reorder, etc. or increasing difficulty in procuring parts
because of discontinuance of production of similar equipment.
3 Computer
Renewal rate: Unit computer About 59%
Data logger computer About 32%
Environmental data-processing computer About 41%
Fuel control computer About 22%
Renewal time: Unit computer
Within the range of 60,000 hours to 180,000 hours
Reasons for renewal: Conceivable reasons that there are many renewals due to degradation damage are
failure attributable to the deterioration of the calculation unit, each sensor, memory,
typewriter, etc. or increasing difficulty in procuring parts because of discontinuance
of production of similar equipment.
4 Analyzer
Renewal rate: Water quality control analyzer About 71%
Fuel analyzer About 48%
Exhaust gas NOx analyzer About 79%
Exhaust gas SOx analyzer About 78%
Exhaust gas O2 analyzer About 82%
Exhaust gas CO analyzer About 29%
Exhaust gas dust analyzer About 34%
Leak oil monitor analyzer About 9%
Flammable gas analyzer About 49%
NH3 analyzer About 35%
Waste water COD analyzer About 30%
Waste water pH meter About 35%
Renewal time: The renewal of the water quality analyzer, fuel analyzer and exhaust gas NOx
analyzer falls within the range of 20,000/30,000 hours to 180,000 hours.
The renewal of exhaust gas SOx analyzer, exhaust gas O2 analyzer, exhaust gas CO
analyzer, flammable gas analyzer, NH3 analyzer, waste water COD analyzer and
waste water pH meter falls within the range of 40,000 hours to 80,000 hours.
Reasons for renewal: Conceivable reasons that there are many renewals due to degradation damage are
failure attributable to deterioration of the calculation unit, each sensor, memory,
typewriter, etc. or increasing difficulty in procuring parts because of discontinuance
of production of similar equipment.
5 Actuator
Renewal rate: Feed water system actuator About 37%
Fuel system actuator About 29%
Starting bypass system actuator About 17%
Air system actuator About 36%
Exhaust gas system actuator About 37%
Renewal time: The renewal of feed water system, air system and exhaust gas system actuator falls
within the range of 60,000 hours to 180,000 hours.
154
Reasons for renewal: Conceivable reasons that there are many renewals due to degradation damage are
occurrence of many failures attributable to deterioration of the control mechanism,
positioner, etc. or increasing difficulty in procuring the parts because of
discontinuance of production of similar equipment.
6 Air source for control, air dryer, air pressure-reducing system
Renewal rate: Air dryer About 42%
Air pressure-reducing system About 17%
Renewal time: The renewal falls within the range of 40,000 hours to 140,000 hours.
Reasons for renewal: Conceivable reasons for renewal are occurrence of many failures as a result of
deterioration owing to change of the control mechanism, tower, etc. or increasing
difficulty in procuring parts because of discontinuance of production of similar
equipment.
7 Transmitter
Renewal rate: Feed water flow transmitter About 65%
Main steam flow transmitter About 61%
Spray flow transmitter About 61%
Fuel oil flow transmitter About 50%
Fuel gas flow transmitter About 45%
Main steam pressure transmitter About 63%
Fuel oil pressure transmitter About 54%
Fuel gas pressure transmitter About 44%
Drum-level transmitter About 60%
Deaerator-level transmitter About 57%
Feed water flow element About 12%
Main steam flow element About 8%
Fuel oil flow element About 22%
Fuel gas flow element About 7%
Conveyor scale About 33%
Renewal time: Renewals of feed water flow, spray flow, fuel oil flow, fuel oil pressure, drum level,
and deaerator-level transmitters fall within the range of 60,000 hours to 180,000
hours.
Renewals of main steam flow and main steam pressure transmitters fall within the
range of 40,000 hours to 200,000 hours.
Reasons for renewal: With respect to degradation damage and damage prevention, conceivable reasons for
renewal are occurrence of many failures due to deterioration of each sensor, signal
converter, etc. or increasing difficulty in procuring parts because of discontinuance of
production of similar equipment.
With respect to performance upgrading, conceivable reasons for renewal are
performance upgrading of equipment and shift of control equipment to the electric
type or digital type.
155
[1] Boiler equipment
Age deterioration phenomena that became obvious in major structural parts of boiler plants (representative
examples)
(1) Long-duration high-temperature creep, high-temperature oxidation/steam oxidation
• Final SH, RH pipe damage
In particular, downgraded portion of points subjected to material change, in-furnace points subjected to
material change
(2) Repeated fatigue due to thermal stress
• Damage of evaporation pipe
Cracks originating from weld zone of fittings adhered to pipe
Damage originated from weld zones of burner, wind box, inspection hole mounting frame
Cracks originating from weld zone of slit-type fin
Crack due to corrosion fatigue from internal surface of pipe at nose, deflection arch and deflection parts.
• SH, RH pipes
Crack originating from weld zone of fixing spacer fixture
• Evaporation pipe, SH and RH pipes (non-heated part)
Crack originating from toe part of stub weld
• Leak of boiler combustion exhaust gas
Seal structural part at intersection part between boiler nose part wall and furnace back wall-suspended pipe
Corner part of side wall part of front and rear wall pipes at heat recovery part
Header guard of RH, Eco, etc. of heat recovery part
Header around furnace bottom and seal structure part of ceiling wall passing-through part at GR port guard
Tube bending part such as TV, inspection hole, burner, manhole, etc.
(3) Repeated fatigue due to long-duration high-temperature creep, thermal stress
• Superheater, reheater header
Crack at weld zone of nozzle
• Main steam piping
Crack originating from internal part of weld zone
Crack at weld zone of branch piping nozzle
Inspection technology and assessment technology having became operational (representative example)
• Boiler tube diagnosis UT system
(Target: Superheater, reheater)
• Major piping diagnosis robot (target: major steam pipe)
• Stack casing inspection robot
• Remaining life assessment by means of destruction test
(targets: evaporation pipe, economizer tube, superheater tube, reheat tube)
• Remaining life diagnosis by means of stress analysis
(Targets: T & Y pieces of major piping, weld zone of tube-adhered fixture, fin-mounting area of tube, support
lug part of tube, header stub)
• Remaining life assessment by means of non-destructive test (A parameter method, void area rate, crystal grain
deformation)
• (Targets: drum, header, header stub)
[2] Turbine equipment
Age deterioration phenomena that became obvious in the major structure of turbine plant (representative
example)
• Breakage of high-pressure rotor
• Surface crack at base R part of high-pressure rotor 1st-stage wheel
• Bending of medium-pressure ROBIN rotor
• Crack at low-pressure rotor wheel stud part
• SCC of low-pressure rotor shrink-fit wheel part
• Lifting of high-pressure part rotating blade
• Erosion and crack on rotating blade of low-pressure part
• Crack on final-stage rotating blade racing wire
• Nozzle erosion
• Crack on rotating blade tenon
• Surface crack on corner part of high- & low-pressure housings
• Crack on medium-pressure housing (origin: repaired weld zone)
• Breakage of the high temperature bolt and damage to the bolt screw thread.
• Crack on major valve casing (origin: repaired weld zone, internal defect)
Inspection technology having became operational (representative example)
• Rotor center hole ultrasonic flaw detection technology
• Rotor center hole magnetic particle flaw detection technology
156
• Rotor center hole hardness-measuring technology
• Rotor center hole replica-sampling technology
• Rotor & casing embrittlement diagnosis technology
• Blade stud part inspection technology
• Tenon ultrasonic flaw detection technology
• Rotor wheel ultrasonic flaw detection technology
• High-temperature bolt (stud bolt) ultrasonic flaw detection technology
Remaining life diagnosis technology having been commercialized
• Rotor, casing, major valve body (crack occurrence assessment, crack propagation assessment)
• Rotating blade (lifting)
In furnace
Side wall
Front wall
157
appear in all areas of boilers, and, for this reason, inspection and repair result in longer time and higher cost. In
particular, heavy damage is found in the metallic substance weld zone of furnace pipe walls, furnace headers and
nozzle weld zones at the reheater header due to fatigue and creep, and fundamental measures are becoming
necessary.
In the future, as these portions are important components of boilers, it is impossible to take fundamental
measures through partial renovation. In addition, from the viewpoint that cost and work will be enormous,
complete blanket renovation of furnace evaporation pipes, headers, etc. is starting to be carried out.
2nd superheater Reheat pipe
pipe (replaced) (replaced) Steam separator
• Generator output (added)
• Main steam temperature
• Main steam pressure
Furnace
evaporation pipe 1st superheater
Fig. 3.1.2.4-2 (replaced)
Outline drawing of Control unit
r(replaced) Evaporator
renovation work for Change of control system
Furnace-side
Himeji No.2 casing Economizer
(replaced)
thermal power Unit
No.2 boiler.
Fuel
Furnace
Burner
Feed water Boiler circulation
valve
pump (added)
Air
Together with this renovation, partial renovation of an accessory plant was performed so that such boilers also
have cutting-edge performance. Further, for the purposes of shortening the renovation construction work period
and securing safety in construction work, the development and introduction of new construction such as jack
down construction (Fig. 3.1.4.2-1) are sought.
(1) Examples of structural improvement measures associated with renovation
(1) Modify the boiler from the skin casing structure to the membrane wall structure to plan a reduction in
thermal stress.
(2) Modify the boiler from a weld construction consisting of the furnace wall and tension plate to a slide
structure to plan the reduction in thermal stress.
(3) Cause the header nozzle part to have sufficient flexibility to plan the reduction in thermal stress.
(4) Modify the furnace wall passing-through part to the double-sleeve structure to avoid a concentration of
stress.
(5) Make the root of the nozzle and weld zone at the fine end smooth to relieve the concentration of stress.
(2) Renovation work examples
In the KANSAI Electric Company’s Himeji No.2 thermal power plant Unit No.2 (325 MW), a subcritical pressure
boiler that began commercial operation in 1964, from 1992 to 1993 blanket replacement of the boiler was carried
out. This unit was originally oil fired; however, in 1980, modification to convert it to LNG fired was made and
since then, this boiler has served as base thermal power. Since its start of commercial operation, this plant has
operated for about 170,000 hours (number of start ups and shut downs: 662), and in addition to normal age
deterioration, due to the fact that this plant has been used for DSS operation from 1985, life consumption due to
low-cycle fatigue advanced in all areas of the boiler, minor problems occurred frequently, and the time required
for inspection and repair increased. Then, as a result of study of a repair program according to the increasing
longevity program, as it is more advantageous to replace the furnace water wall part completely than to repeat
minor repairs in terms of cost, then it was decided to carry out total replacement. Further, together with
renovation, performance upgrading including improvement of thermal efficiency and acceleration of the time
required for start up is planned through modification from a constant-pressure to a variable-pressure operation
method. (Fig. 3.1.2.4-2).
3.1.2.5 Technology and construction method for shortening of the term of periodic inspection work
In addition to the peak in the summer season, for the purpose of responding to firm growth of demand in the
winter season, the timing of periodic inspections tends to be concentrated in spring and autumn. On the other hand,
the term of periodic inspection work tends to become longer due to the increase in the amount of repairs
associated with aging of plants, and in the future, as the aging of large-capacity machines will also proceed,
further efforts to shorten the term of periodic inspection work are sought.
As a method to plan the shortening of the term of periodic inspection work, in addition to the effective
classification and planning of repair work associated with aging, improvement of construction method that
includes the following are also pursued.
• Improvement of work efficiency through mechanization and broader use of robots
• Improvement of work efficiency through labor-saving tools
• Cutback in amount of works through blanket replacement of large parts (service, repair, etc.)
In addition, measures will be also be implemented from the viewpoint of the plant (Table 3.1.2.5-1), including:
• Earlier start of work through forced cooling stop of the turbine
• Improvement of workability through scale-up of manholes
158
Table 3.1.2.5-1 Improvement examples for shortening of the term of periodic inspection work
Examples Outline
Adoption of forced cooling system for turbine Introduce the outside air into high- and medium-pressure casings through the injection of cooling
air or by means of vacuum pump to shorten the cooling time.
Adopt a high-performance oil-flushing system. Use the flushing system with a fine-mesh filter.
Have gas turbine rotor spares. Have the gas turbine rotor of the combined-cycle generator as a spare to replace it at periodic
inspection.
Have steam turbine rotor spares. Have the steam turbine rotor for geothermal heat as a spare to replace it at periodic inspection.
Adopt a gas turbine static blade-sealing alignment system. Although alignment at replacement was performed at the manufacturer’s factory, alignment has
become available through installation of the system at site.
Adopt a casing-tightening hydraulic bolt. Change the high-pressure turbine casing-tightening bolt from the shrink-fit type to the hydraulic
tension type.
Modify from MHG to EHG. —
Have one set of EHG parts spares. Have one set of EHG parts as spares to replace them at inspection.
Additionally install an overhead traveling crane. Install an overhead traveling crane additionally.
Making the overhead traveling crane faster. Make traveling and hoisting speed faster to plan effective use of the crane.
Develop scaffolding at the furnace bottom part. Carry in one set of folded stages from the furnace bottom to extend it on the furnace bottom.
Adopt a mobile clinker hopper. Change the clinker hopper to the mobile type to facilitate carry-in of scaffolding.
Adopt a turbine rotor dry horning unit. Change the work form from manual work to work with the horning unit to plan greater efficiency of
work.
Adopt a hydraulic torque wrench. Adopt the hydraulic torque wrench for crossover pipe flange-tightening work at low-pressure casing.
Install a lifting unit for dismantling of major valves. Adopt a simplified lifting unit for lifting work of the main check valve, etc. to plan greater
efficiency of work.
Adopt a hydraulic bolt for coupling. Tighten the coupling by means of a hydraulic tension bolt.
Improve in-furnace scaffolding. Change the scaffolding from steel pipe scaffolding to steel fit scaffolding.
Install a floor for carry-in of boiler materials. Install an out-furnace stage for carry-in of in-furnace scaffolding and for material storage space.
Install a shutter at the boiler sound isolation wall opening. Install an opening at the sound isolation wall of the boiler to facilitate carry-in of materials, etc.
Conduct dismantling and inspection work on the electric valve with greater efficiency. Change the power supply connection of the electric valve to the connector system.
Contrive dismantling and assembling jigs for the coil-end cover of the generator. Fix the bottom cover to the jig and then cause it to rotate to facilitate removal.
Adopt an ultrasonic expansion-measuring instrument Measure expansion of bolts by means of the ultrasonic measuring instrument.
Turbine blade clearance-measuring device Insert the sensor into the clearance between the turbine blades to perform automatic measurement to
process its data.
Adopt a laser-type centering measuring device. Measure turbine alignment by means of a laser to calculate the corrected value automatically.
Adopt a turbine casing lifting-level supervisory unit. Monitor parallelism of the housing to be lifted by installing an ultrasonic-type distance sensor at 4
corners to measure it.
Install a crane for light parts. In addition to an overhead traveling crane, install a crane for lifting light parts.
Rotor center hole horning unit Unit that performs horning of the turbine rotor center hole automatically.
Adopt a hydraulic jack for dismantling of housing. Cause the measuring sensors installed at 4 corners of the housing to synchronize with the hydraulic
jack to lift it horizontally.
Adopt a jig for groove alignment of the boiler-cooling wall pipe. Jig for groove alignment of boiler water-cooling wall pipe.
Upsize the boiler manhole. Upsize the bore of the boiler manhole to plan greater efficiency.
Develop an internal surface inspection system of the boiler header part. Insert it through the header inspection hole to make observation by means of TV and observation
with an optical microscope.
159
3.1.2.6 Support system for creating a work plan for increasing longevity
In order to continue stable operation of an aged thermal power plant after 20 years or more from its construction
and start of operation. While maintaining the economics and its function, identifying the function, performance
and soundness of equipment and presentation (recovery from deterioration) are performed more efficiently than
conventionally.
For this reason, a support system to create a work plan for increasing longevity that takes plant reliability and
economics into account has generally been introduced and made use of.
Creation of a work plan for increasing longevity is performed along each step of flow in Fig. 3.1.2.6-1.
1 Selection of critical equipment (Fig. 3.1.2.6-2)
Assuming that the service period will be 60 years, the operation time, 400,000 hours and the number of start
ups and shut downs, 5,000, select equipment for which remaining life control is believed to be necessary out of all
equipment comprising the unit. Assess the probability of the occurrence of failure, effect of failure on output when
it occurs, term of recovery work and cost, safety (social influence level), etc. comprehensively by means of the
FMEA technique.
2 Investigation of the background of accidents and failures
Collect and organize the records of accidents and failures regarding the selected critical equipment, and
investigate the failure mode, life consumption factor, etc. during a long-term service period.
3 Breakdown and defragmentation of equipment (selection of critical points)
Select critical equipment.
Operation history
Future operation conditions
Marginal processing value
Fig. 3.1.2.6-1 Flow in creation of work program plan list for increasing longevity work
Equipment
Measuring device
Electric device
Boiler system
Turbine system
Effect-level assessment
160
Break down the selected critical equipment to the group that conceivably has the same structure, function, and
design condition, and then defragment them based on the detailed structure to select “Point to which maintenance
control should be performed based on life assessment.”
4 Selection of critical portion (Fig. 24)
Critical point :
Dummy groove
Critical portion :
Heat group groove Critical point : Center hole
bottom Critical portion : Control stage bottom
Initial failure mode : Crack Initial failure mode : Crack Critical point : Rotor body
Life consumption factor: Life consumption factor: Critical portion : Central part and others
Low-cycle fatigue Creep + Low-cycle Initial failure mode : Deformation
Low-cycle fatigue + fatigue Deterioration of
High-cycle fatigue characteristics
Life consumption factor :
Creep, softening,
embrittlement
Processing
Output
limit
Limit processing
Computer
value
Consumed life
Temperature
difference
Life (Year)
consumption
unit life
Repetitions
161
Table 3.1.2.6-1 Example of plan list for increasing longevity (Unit: million yen)
Fiscal
System 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010
Boiler related 2226 83 62 15 35 10 268 3356 17 44 17
Turbine related 712 85 1 35 37 83 95 1203 103 21 70
Electric related 12 14 2 406 828 374 54 116
Measurement related 12 20 70 300 320
Total 3002 168 77 50 74 93 789 5457 494 419 523
162
3.2.1 Causes of damage to boiler equipment
(1) Trend of damage
An example of analysis of the ratio of aged deterioration damage for each component of a boiler and the
damage ratio of its pressure-retaining parts by each cause are shown in Fig. 3.2.1-1. Such pressure-retaining
components as the furnace wall, super-heater, re-heater, economizer, piping, etc. account for 67% of the entire
boiler equipment. Thermal fatigue, corrosion fatigue, and creep damage account for 83% of the causes of total
damage. As measures to improve the reliability of thermal power generation plants, it is important to prevent such
fatigue, corrosion fatigue, and creep damage from occurring to such pressure-retaining components.
Others
7%
Others Corrosion
14% 5%
Non-pressure-retai Wear
Furnace 5%
ning components
4%
wall
31%
Fan Ratio of occurrence Cause of damage to Thermal
Creep pressure-retaining
10% of failure for each fatigue/
15% components
component of boiler corrosion
equipment fatigue
Valves 68%
5%
Piping SH/RH/ECO
16% 20%
• Corrosion by high
temperature
164
Table 3.2.2-1 Portions where thermal stress is generated and measures to reduce the stress
Portion where fatigue damage Mechanism of generation of
Portion Measures to reduce stress
occurs stress
① Furnace wall If the boiler water temperature Arrange the fin edge in a large
should change upon boiler arch shape
start/stop operations, temperature R-machining of fin edge
difference occurs between the
Cool water
furnace wall and the sub-wall or
between the sub-wall and the rear
smoke duct wall, which generates
stress on the fin edge of the R-machining
(9) 2 A h Arch
furnace wall.
② Furnace wall seal box weld If the boiler water temperature Change the shape of the seal box
should change upon boiler corner to an arch.
Concentration
of stress
start/stop operations, temperature Bend the seal box side in 2 steps.
difference occurs between the
furnace wall piping and the seal 2-step
bending
box, by which stress concentrates
R corner
Tool box at the corner.
③ Fixtures mounted on furnace If the boiler water temperature Change the structure of the
wall should change upon boiler furnace wall piping and mounted
Tension plate start/stop operations, temperature fixture to a sliding structure.
difference occurs between the Tension plate
Slide
④ End bar and skin casing for The entire portion tends to deform Change the structure of the
End bar due to the temperature difference ceiling piping and end bar to a
the hole of the ceiling Welded portion
between the front- and rear-end sliding structure.
the ceiling
Piping on
bards at the ceiling hole, but is Change the skin casing to a 2-step
locked by the ceiling piping, bent type.
resulting in the generation of 2-step-type skin
stress on the welded portion. Due casing
End bar
to the temperature difference
Deformation between the end bar and the skin Piping on
the ceiling
casing, cracking occurs on the
skin casing.
⑤ Skin casing below Due to the temperature difference Change the skin casing to 2-step
economizer between the wall piping projected bellow type.
surrounding the rear smoke duct
and hopper, stress is generated on
the skin casing, resulting in
cracking.
165
Damage caused by heat fatigue Damage caused by corrosive fatigue
Generation of Generation of
high stress high stress
Table 3.2.2-1 Portion where thermal stress is generated and measures to reduce the stress
Portion where fatigue damage Mechanism of generation of
Portion Measures to reduce stress
occurs stress
⑥ Nozzle of super-heater and Temperature difference occurs • Change the nozzles to the
re-heating pipe head between the nozzles during flexible type.
start/stop operations, and bending
stress is generated on the welded
Piping on
portion that has been locked Flexible
the ceiling between the nozzles and ceiling
hole.
⑦ Joint welded by dissimilar Due to the difference in the By using Inconel-family welding
metals carbon content, carbon migrates electrodes and by reducing the
to the metal to be welded from linear expansion difference,
linear thermal
Coefficient of
Inconel welding
low-alloy steel, yielding a reduce the stress. Prevent the
expansion
electrode
Present
decarbonized layer as a result, strength from declining by
Improved
style
style
and the strength on the low-alloy preventing the carbon from
side declines. By the difference in migrating.
thermal expansion between the
SUS rod austenitic stainless steel to be
welded and the low-alloy base Welding at factory
SUS steel steel, thermal stress is generated using Inconel welding
Cr-Mo steel electrodes
on the portion welded. Because of
its high temperature, creep
damage also occurs.
⑧ Saddle spacer welding Within a structure supported by a Employ a flexible spacer.
portion spacer fixed by welding to the Slide
Fixed
Welding-type hanging pipe of the
saddle Fixed
horizontal-type
super-heater/re-heater, thermal
stress is generated on the Flexible saddle
spacer
spacer-welded portion due to the
temperature difference between
the upper and the lower pipes.
⑨ Welded portion of If the air vent pipe and drain pipe Change the small-diameter pipe
small-diameter nozzle of pipe of pipe header are the type of to a flexible type. The form of
Deformation
header (29) Pi i ti such structure as being locked in nozzle of pipe heater should be
Piping the housing hole, thermal stress is butt welding type.
reaction Flexible bending
force
generated at the welded portion of piping
the nozzle of pipe header.
Hole to
be fixed
166
Portion where fatigue damage Mechanism of generation of
Portion Measures to reduce stress
occurs stress
⑩ Welded portion to fix the Due to the temperature difference Separate the anchor plate to fit it
anchor plate Portion where
between the anchor plate and by full arc welding and make the
cracking occurs furnace wall piping occurring by size smaller.
Filler plate Anchor plate
start/stop operations of a boiler,
Tie bar Stand-off
stress concentrates at the welded Stopper
portion of the anchor plate. Filler plate
Driber
Anchor plate
Stand-off
⑪ Membrane-edge connecting Due to the temperature difference Refresh the connection membrane
waterwall and cage walls between the waterwall and cage edge and provide R-machining to
Membrane piping occurring by start/stop the welding stop end.
Portion operations, stress concentrates at
Waterwall where Membrane
pipe cracking the connection and membrane
occurs edge. Waterwall
pipe
Support Support
Improved
Base pipe ring concentrates at the liner-welded Desuper-heater main body Spray structure
Protection cylinder Support Protection nozzle (pin type)
portion. cylinder
Fitting of liner
(Welding type) Pin
Portion where
cracking occurs Stopper Pin
⑭ Ceiling hole Due to the temperature difference Use a sleeve through the ceiling
between the crown and the hole and avoid direct welding of
Crwon
piping, stress concentrates the crown to the piping.
causing cracking to occur. Crown
To add a
sleeve
Ceiling
piping
Ceiling
piping
⑮ Connection of loop pipes When there is a temperature Use a sliding spacer at the portion
difference at operation start, where high temperature is
Tie rod Sliding spacer
cracking occurs at the portion transmitted and to avoid any
where a linkage fixture has been locking. Change the tie lag in the
installed due to stress rear heat transmission portion to
concentration. an oval-shaped lag to soften the
Hanging loop
pipe concentration of stress.
⑯ Inner casing of ceiling The corner casing cannot absorb Use a corrugated-type expansion
enclosure the expansion force from 3 sides, at the corner.
Corrugated-type
and cracking causes gas leakage. expansion
167
However, in a corrosive environment, strength against fatigue declines, which causes cracking at the inner face
within a pipe by corrosion fatigue.
As a characteristic of a cracked surface caused by corrosion fatigue, many cracks are accompanied by pits
caused by the corrosion along the cracks.
As basic countermeasures, such actions to soften the thermal stress are considered important. In such a case, it
is required to change the tension plate support to a sliding type and improve the structure so that the thermal stress
may be softened.
Examples of other corrosion fatigue are introduced below:
① Straight fin end of economizer piping (Fig. 3.2.2-2)
The occurrence of cracking was experienced at the straight fin end of the economizer piping, caused by thermal
stress accompanied by intermittent water supply in order to keep the drum at a constant level at the operation start
of the boiler.
Cracking has started from the inner surface of the piping. Corrosive fatigue is the cause.
② Ligament of the pipe header at the inlet of the economizer (Fig. 3.2.2-3)
The occurrence of cracking was experienced at the ligament of the pipe header at the inlet of the economizer
due to the same cause as above. This was also caused by corrosion fatigue.
(4) Mechanical fatigue
In the case of mechanical fatigue, the cracking is a type of transgranular cracking in general. The ruptured face
has a fine fatigue face, and no extension by rupture was detected.
Fig. 3.2.2-3 Example of corrosion fatigue of the inner ligament of the pipe header nozzle at the inlet of the
economizer
(5) High-temperature corrosion
The surface stainless steel pipe affected by high-temperature corrosion has been damaged by corrosion in a
pockmarked fashion. The corroded portion is composed of an oxide layer – a polysulfide layer – a carbonized
layer – base metal from the outer piping surface. From the viewpoint of microstructure, the corroded and
carbonized structure of grain boundary is found. A drop in expansion as well as a drop in strength can be
detected.
168
Table 3.2.2-2 Classification of measures to improve bearing force
Phenomenon Cause Measures Subject portion
Corrosion fatigue Change of structure and Fixture welded to furnace wall piping,
shape, water quality ligament at the inlet of the economizer
control
Wear Coal ash, soot blow Protector, pipe thermal Furnace wall, super-heater, re-heater
spraying
Conventional test
Stress (MPa)
specimen
Time of rupture
Comparison of strength against creep rupture between a conventional
test specimen of 1 Cr 0.5 Mo Steel and a miniature test specimen
170
Table 3.2.3-1 Non-destructive method of assessing the remaining life of components affected by creep/fatigue damage
Method as described Low-alloy steel Steel
Subject in Attachment 3 of the
Method of assessing remaining life
damage Electricity Utilities Welded Welded
Base metal Base metal
Industry Law portion portion
Creep Deposition intergranular distance
{ { ⎯ ⎯ ⎯
damage method
Hardness-measuring method { ⎯ ⎯ { ⎯
Structure comparison method { ⎯ { ⎯ ⎯
AC electric resistance method { ⎯ { ⎯ {
Void (cavity) area ratio method { ⎯ { ⎯ {
Void density method { ⎯ { ⎯ {
A-parameter method { ⎯ ⎯ ⎯ ⎯
Crystal grain deformation method { { { ⎯ ⎯
Carbide structure-measuring method { ⎯ { ⎯ ⎯
Ultrasonic method { ⎯ { ⎯ ⎯
Structure-quantifying method ⎯ ⎯ { ⎯ ⎯
CMA density spectrum method ⎯ ⎯ { ⎯ ⎯
Fatigue Microscopic-crack method ⎯ { { ⎯ ⎯
① Creep damage
(a) Deposition intergranular distance method
This method is used for the assessment of creep damage of low-alloy steel base metal. Low-alloy steel is a
material whose strength against creep has been raised by depositions and shows ductile creep damage. When used
for many hours in a high-temperature atmosphere, the intergranular distance of this disposition becomes larger
and, at the same time, resistance against deformation declines, causing the creep to accelerate. This phenomenon
is represented by the creep distortion–time curve in general. The change depends on the temperature and stress of
the subject component. By measuring the intergranular distance between particles of disposition, the creep
distortion at the time of assessment can be obtained. Therefore, the behavior of creep distortion thereafter can be
predicted, and the creep remaining life can be assessed. The intergranular distance of disposition is obtained by
image processing of the replica taken out from the subject component using an electrolytic discharge-type
scanning electron microscope (Fig. 3.2, 3-2).
Disposition
Scanning
Replica line
Point
Mean free-path
Creep rate constant
Scanning-type electron
microscope Average intergranular
distance (µm)
Fig. 3.2.3-2 Disposition intergranular distance method
171
(b) Hardness-measuring method
The crystal grains of 9 Cr base metal steel are very fine, and this base metal has a hard structure of initial
hardness. Different from low-alloy steel, no metallic structural change can be detected even when creep damage
grows. However, its hardness tends to drop gradually.
Therefore, by measuring the hardness and referring to the master curve that indicates the relationship between
the hardness and the amount of damage, the life consumption ratio can be assessed (Fig. 3.2.3-2).
Vickers
hardness
172
Replica Extracted replica
Component surface
(etched surface)
Life consumption
Damage factors Comprehensive ratio by creep
Microscopic Deposition
damage breakage (%)
Mechanical
distribution
category
damage structure
The creep damage of the component affected by welding heat from these steels is a type of fragile damage and
generates creep voids at the grain boundary. As the generation of voids increases, the electric resistance tends to
become stronger (Fig. 3.2.3-4). The amount of damage is assessed by using the electric resistance ratio of unused
material and the electric resistance ratio of the component being assessed, and by referring to the master curve
indicating the relationship with the amount of damage. Assessment accuracy has been improved by making it
173
easier to grasp the level of damage proximate to the surface by using an alternative current. In addition, it is
required in this method to spot weld a platinum wire to the subject component. If an electrode has once been
installed, building of a scaffold, thermal insulation, removal/restoration of the exterior plate, and polishing of the
subject component for inspection are not required thereafter. Therefore, the costs for inspection can be reduced. In
addition, it is possible to make measurement at any time during operation. This method can also be used for
monitoring the main piping, etc.
(e) Void (cavity) area ratio method
As shown in Fig. 3.2.3-5, voids are generated at the grain boundary when the HAZ portion of low-alloy steel or
9 Cr steel is affected by creep damage. The number of voids increases as the damage grows. The voids become a
crack after growing/combining (namely, the area of voids increases), and finally result in the rupture of the
component material. In this method, the ratio between the total area of voids generated within the observation
visual field and the total observation visual area is defined as a void (cavity) area ratio. Using this ratio together
with the master curve prepared by its correlation with the degree of creep damage, the life is assessed in this
method (Fig. 3.2.3-5).
Replica
Scanning-type
electron microscope
Regression curve
99% reliable section
99% reliable section of
creep damage ratio
Incidentally, the behavior to generate voids is different in such low-alloy steels as 2.25 Cr-1 Mo steel, etc. and 9
Cr steel. It is required to use the master curve suitable for the respective type of steel.
(f) Void density method
The ratio between the number of voids in the observation visual field and the observation area is defined as
cavity density. Referring to the master curve indicating the relationship between the cavity density and the amount
of damage, assessment of the life of the component subjected to assessment is carried out in this method.
(g) A-parameter method
This is a method to be used for the assessment of creep damage at the HAZ portion of low-alloy steel. This
method was developed by English researchers. Creep voids generated as creep damage grows are generated at the
grain boundary. Draw an optional scanning line in the metal structure of the subject component. The ratio of the
number of grain boundaries where voids have been generated against the number of grain boundaries that
intersect this scanning line is defined as the A-parameter. The life of the component subjected to assessment is
assessed in this method by referring to the master curve indicating its relationship with the amount of damage (Fig.
3.2.3-6).
174
Amount of creep damage (%)
Relationship between A-parameter and life
consumption ratio by creep rupture
Maximum
diameter
Deformation count Sm (degree)
Crystal
grain
Frequency
Direction of stress
• Applied to the assessment of creep damage of Cr-Mo steel
base metal
(a) New material • Method of assessing the remaining life focusing on the fact
Piping material (500-650°C) that the crystal grain deforms as the creep damage grows
Heat transmission pipe material (570-600°C)
Formal
distribution
Fig. 3.2.3-7 Assessment of creep damage to Cr-Mo steel base metal through the crystal grain deformation method
Noise value
Frequency
analyzer st
1 bottom echo Life ratio
Component for
assessment
176
Magnetic powder
copying film
Magnetic powder
Oxidation scale
Magnetic
field
Crack detection
boundary
177
Table 3.2.4-1 Various types of inspection methods and related automation
Method of inspection and
Subject Damage to material Automation
detection
Furnace waterwall (1) Thermal fatigue of PT, MT Automatic inspection
piping piping external metals UT from outside furnace device using a
(2) Inner piping corrosion High-frequency array UT multi-sensor within the
fatigue Spiral UT furnace
Coil of (1) Creep Replica method, hardness Void recognition device by
super-heater, method image processing
re-heater, and (2) Fatigue PT, MT
economizer Replica method
(microscopic method)
(3) High-temperature Inner piping UT Automatic-measuring
corrosion, wear, and robot
thickness decrease
(3) Steam oxidation scale High-precision UT
method
(4) Wear of horizontal High-velocity laser Automatic inspection unit
heat-transferring method
piping Inner piping UT
UT thickness gage for
narrow portion
Pipe header and (1) Type IV crack, inner TOFD method Image-processing device
main piping crack Electronic focus sector
scanning
Ultrasonic noise method
W elding material
Base material Base material
Wave diffracted on
the crack top
Wave diffracted on
the crack bottom
Type I: Crack in welded metal
Type II: Crack classified as Type I, which has expanded from Wave reflected
on the bottom
the welded portion to the portion affected by heat
(HAZ) Crack
Type III: Damage to the rough-grain area of the portion Diffracted
affected by heat (HAZ) wave
Type IV: Damage from the fine-grain area of the portion
affected by heat (HAZ) to the range of the partially Direct reflection wave (same as conventional one)
transformed area
Type III damage (damage in a rough-grain area) appears on the external surface of a pipe, whereas Type IV
damage (damage in a fine-grain area) occurs within a thick wall pipe and expands toward the surface. Impure
substances contained in the steel play an important role in Type IV cracks.
(2) Inspection method for Type IV cracks
Typical inspection methods for Type IV cracks occurring within a pipe having a thick wall are explained below.
The inspection method is used alone or jointly with other methods.
① TOFD method
As an inspection technology able to assess Type IV cracks occurring from the inside of a thick wall precisely
and quantitatively, the TOFD (Time of Flight Diffraction) method has been developed and put to practical use,
which is an ultrasonic wave flaw detection method using 2 search units for transmission and receipt. A comparison
with the conventional angle beam method is shown in Fig. 3.2.4-2.
The conventional method was in principle designed so as to catch reflecting echoes from a defect. Therefore,
there were some cases where inspection was not possible depending on the direction of the crack. It was also
178
difficult to capture the defect size in a quantitative manner.
On the other hand, the TOFD method catches the wave diffracted from the tip end of a crack. Therefore, it is
not affected by the direction of the defect. In addition, it can assess the length (depth) of a crack based on the
transmission time of the diffracted wave. As a result, inspection in a precise and quantitative fashion has become
possible.
② Electronic focus sector scan ultrasonic testing
The principles of measurement by ELFOSS UT are shown in Fig. 3.2.4-3. This device can perform wide-angle
scanning by focusing an ultrasonic wave beam through the delay circuit to improve resolution and defect
inspection accuracy. Two search units are used for the TOFD method, whereas this device has such a characteristic
that inspection of the narrow portion is made possible because wide-angle flaw detection is performed by only 1
search unit.
Trigger pulse
for activation
Delay circuit
Vibrator
Angle of
deflection
Focus
Electronic focusing by Sector scan by delay Electronic focus sector
delay circuit circuit scan
If the activation timing of If the activation timing of If the timing and duration
the vibrator is the vibrator is changed at of the activation of the
changed with the the same interval, the vibrator is changed from
same interval in the ultrasonic wave beam is time to time, the direction
right and left deflected. In addition, the can be changed
directions, an deflection angle can be continuously by focusing
ultrasonic wave freely set by the duration an ultrasonic wave beam.
beam focuses. In of the timing.
addition, the focal
depth can be freely
set by the duration of
the timing.
179
Scan a search unit and apply gate by Clarification of the points of damage
splitting the corresponding time width. for image processing
Fig. 3.2.4.-4 Image processing of flaw detection results through the ultrasonic noise method
The water vapor oxidized scale generated in the steam system peels off during operation and accumulates in the
U-shape pipe of the super-heater piping, resulting in its explosion. Its fragments may fly over to the turbine and
damage the blade.
180
② Timing of chemical cleaning
For the timing of chemical cleaning after the start of operation of boiler equipment, the boiler manufacturer
specifies the standards of cleaning depending on the amount and thickness of adhered scale. On the other hand,
the operators at electric power companies also specify their own respective standards. The standards commonly
used for cleaning are shown in Table 3.2.5-2. The value mentioned there is only a general guideline. Therefore, it
is desirable if an independent cleaning timing is established. In addition, this value should be determined based on
the portion where the maximum amount of scale adheres to individual boiler equipment. Full care should be paid
to any change in the portion where the maximum amount of scale adhered due to a change in the boiler operation
method or fuel change.
Table 3.2.5-2 Amount and thickness of adhered scale for which chemical cleaning is required
Normal pressure
Beyond boundary
8Mpa class 12Mpa class 18Mpa class
pressure
Type
⎯ 90 ~ 135 75 ~ 105
Coal-fired boiler ⎯
⎯ 400 ~ 450 250 ~ 350
Coal/oil 90 ~ 120 75 ~ 105 60 ~ 90
mixture-fired ⎯
boiler 300 ~ 400 250 ~ 350 200 ~ 300
75 ~ 105 60 ~ 90 45 ~ 75 24 ~ 36
Oil-fired boiler
250 ~ 350 200 ~ 300 150 ~ 250 80 ~ 120
Gas-fired boiler Same as above Same as above Same as above Same as above
Note 1) The upper row in each column indicates the amount of adhered scale (mg/cm²), the and lower row indicates the scale
thickness (µm).
Note 2) The amount of adhered scale is the value at the flame side (180°) of the inner evaporation piping.
Note 3) The amount of a once-through boiler of 18 Mpa class or smaller shall be 2/3 of the value shown in above table.
Note 4) Even if the actual values are less than above, it is recommended to carry out chemical cleaning when the boiler has been
operated for 50,000 hours or longer.
181
Table 3.2.5-3 Examples of chemically analyzed scale ingredients
Average
adhering Chemical content
amount
Boiler Pipe specimen (mg/cm2)
Refractory
Fe3SO4
by acid
Al2O3
Cr2O3
MgO
MoO
MnO
P2O5
ZnO
CaO
NiO
Cu
A Right-side wall pipe 65.3 58.3 1.9 1.1 <0.1 <0.1 10.3 13.3 10.6 - - - 2.1
B Front wall pipe 25.4 33.0 34.5 15.1 0.7 14.5 <0.1 <0.1 0.3 - - - 0.2
C Front wall pipe 20.4 73.0 2.8 10.0 0.9 <0.1 0.8 1.7 4.9 - - - 1.9
D Front wall pipe 24.1 97.5 <0.1 <0.1 <0.1 <0.1 <0.1 0.1 - 1.8 - 0.7 <0.1
E Front wall pipe 23.4 97.9 <0.1 <0.1 <0.1 <0.1 - - - - - - 0.7
F Front wall pipe 9.6 97.9 <0.1 <0.1 <0.1 <0.1 <0.1 0.2 - - - 0.5 <0.1
G Secondary 38.4
65.9 <0.1 <0.1 - 11.3 - - <0.1 17.8 1.5 1.7 0.3
super-heater
H Re-heater 125.0 95.4 <0.1 <0.02 <0.1 <0.2 - <0.4 - 1.8 0.9 0.4 1.3
I Main steam pipe 125.3 88.1 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 3.3 0.8 <0.5 -
Note 1) A: Boiler for own power generation (VU-60) 6.8 MPa 60 t/h
B: Forced circulation boiler (Mitsubishi) 19.2 MPa 860 t/h
C: Natural circulation boiler (Hitachi) 17.2 MPa 1,135 t/h
D: Once-through boiler 26.3 MPa 1,640 t/h
E: Pressure-variable once-through boiler (AVT) 25.0 MPa 2,300 t/h
F: Pressure-variable once-through boiler (CWT) 25.0 MPa 2,300 t/h
G: Once-through boiler (super-heater piping: SUS316HTB) 26.9 MPa 1,500 t/h
H: Pressure-variable once-through boiler (re-heater piping:STBA24) 25.0 MPa 2,300 t/h
I: Once-through boiler (main steam piping:STBA24) 25.0 MPa 1,900 t/h
Note 2) A –F: Adhered amount on flame side
G – I: Adhered amount around entire circumference
Outer
layer
Inner
layer
Base
material
Photo 3.2.5-1: Corrugated scale of AVT treatment Photo 3.2.5-2: Steam-oxidized scale
boiler (x 100 magnification)
With respect to boiler E, fine-grain Fe₂O₃ from CWT (combined water treatment) adheres to the magnetite, and
the scale has smooth surface.
(e) Boilers G, H, and I generate vapor-type scale. Cr-Mo steel (low-alloy steel) has been used for these
boilers. Two-layer scale, called steam-oxidized scale; one in the neighborhood of piping materials with a
high content of chromium and the other at steam side with a high content of iron oxide are generated as
shown in Photo 3.2.5-2.
182
Table 3.2.5-4 Operation of a boiler and required cleaning process
Cleaning with
Cleaning with
Final washing
Washing with
Washing with
neutralization
Prevention of
Cleaning by
degreasing
with water
ammonia
Flushing
rust by
water
water
acid
During construction { ⎯ U U { { { U
Copper content: high { { ⎯ { { { { U
After
operation
Copper content: low { ⎯ ⎯ ⎯ { { { U
Copper content: none { ⎯ ⎯ ⎯ { { { U
Remarks {: Implement. U Implement if necessary.
183
Investigation of the subject of cleaning
Inspection
z Visual inspection
Dissolution test z Amount of corrosion to be checked
by a test piece
z Scale dissolution test z Amount of scale removed by
z Material deterioration test cleaning
z Investigation of customer’s
environmental conditions such as
wastewater standards, etc. Summary
z Availability of wastewater treatment
equipment at customer side z Report of cleaning implemented
z Experimental wastewater treatment z Advice regarding maintenance and
water treatment method
Study of wastewater treatment system z Checking of operation after cleaning
184
N2 gas Actual construction line
Temporary Temporary construction
Steam drum level gage Pressure gage
Front/rear
Flow meter
supply line
walls
Side wall
Side wall
Sampling
Water
Thermometer
Mixing header
Mixing heater
Inspection nipple
Blower
Ejector
Evaporator
tank
Economizer
To blow line
185
3.2.6 Circulation Pump
(1) Preventive maintenance of circulation pump
Circulation pumps for boilers have been employed for boiler equipment having a capacity of 150 MW or more
since around 1955. The circulation pump is divided into the injection type and the glandless type (canned motor
type, submerged motor type). Currently, about 400 units of these 2 types of pumps are operated for domestic
thermal power generation. Many non-conformance events occurred at the initial stage of introduction. As a result
of structural improvement and completion of the details for inspection items thereafter, such non-conformance
events have been drastically reduced and the reliability has been largely improved. However, 30 years have
already passed since the installation of some circulation pumps as shown in Fig. 3.2.6-1. Some of them are being
replaced gradually, but more than half of them have been used for 15 years or longer. The preventive maintenance
of such units has become a critical issue. (The descriptions from the next section are examples of circulation
pumps made by Fuji Electric.)
Number of delivered units (unit)
Total number
of units
186
① Non-conformance events
As explained above, non-conformance events have been reduced to date, and the reliability of the circulation
pump of boiler has been largely improved. However, there still remain many plants for which no structural
improvement has been implemented so far. It is required therefore to recheck the non-conformance events in the
past and reflect their results in the completion of details of inspection items and on the plan for repair.
Non-conformance events of major parts are outlined in Fig. 3.2.6-2, which shows the deterioration phenomena
and renewal cycle of major parts (renewal cycle with addition of the effect of the bearing force improvement plan
to the past experiences).
② Guideline for implementation of preventive maintenance and inspection
Inspection items are divided into “general inspection items” and “special inspection items.” General inspection
mainly involves visual inspection, whereas non-destructive testing is the main item of special inspection, which
should be started from the 10th year after the start of operation to obtain remaining life assessment data.
Concretely, the target regular inspection cycle should be set at 4 years, and a long-term plan of “details for
checking/inspection items” and “details for repair items ”should be developed Items to be implemented should
be confirmed at the start of the respective regular inspection.
③ Concept of measures for improvement of bearing force and examples of implementation
Measures for improvement of bearing force of the circulation pump of boiler equipment are promoted under the
2 concepts below, aiming to respond to any change in the operation method of power generation plants
(conversion to WSS/DSS), extension of the inspection cycle, and prolongation of operation life:
(a) Improvement of structure, materials, and work method
(b) Enrichment of inspection items (early detection of non-conformance and early countermeasures)
Typical examples of implementation are shown below:
i) Forged pump case
The conventional pump case was a cast product of the volute type. As a measure to improve the bearing
force of the pump case, a spherical-shape forged pump case has been employed for about 15 years.
Compared with the volute-type cast pump case, the spherical-shape forged pump case is simple in its
configuration and the reliability of its materials is high. It is suitable for a plant with frequent start/stop
operations in a high-temperature, high-pressure atmosphere (plants using DSS, etc.)
ii) The motor stator coil has been changed to cross-linked polyethylene wire.
Coils manufactured before 1980 were made of PVC wire, which involved the issue that the rewinding
cycle was short because hardening/fragility of the insulation coat was accelerated due to reduction of
the plasticizer.
iii) Employment of a single-basket-shaped stator of the closed slit type
The double-basket-shaped stator of the open slit type was used as a standard stator in the past. DSS
operation (repeated transient vibration torque and/or thermal stress at the start of operation) was not
considered in its structure. As a measure for DDS operation, a single rotor of the closed slit type has
been employed.
iv) Implementation of special precise inspection
Visual inspection is more than enough for the initial stage of plant operation (within 10 years). However,
after 10 years when the renewal cycle timing of parts approaches, special precise inspection mainly
composed of non-destructive testing is carried out in addition to visual inspection. Through early
detection of and early action against any non-conformance by determining the timing of renewal, the
life of parts can be prolonged.
187
3.2.7 Fan
(1) Measures to improve reliability and guideline for maintenance and inspection
The present time is called a maintenance age. The number of social systems and production systems subjected
to maintenance are accumulating at a continuously increasing speed. According to a certain trial calculation, the
ratio of costs for maintenance was 10% of social capital investment during the 1970s, whereas it increased to 30%
during the 1990s and to 50% by 2020. Under these circumstances, maintenance costs keep increasing; how to
cope with this in a quantitative manner, how to improve cost efficiency keeping improvement of reliability, and
how to select the type of acceptable maintenance have become serious issues.
Because the fans installed at power generation plants are kept in operation for a long period of time from the
start of operation until the time they are disposed of, the accumulated number of units has been increasing. It is
required to make clear what inspection items are to be applied to these fans and to implement them under a
controlled cycle and implement feedback and feedforward without any reserve. Because efficiency and
rationalization of maintenance costs is directly linked to the management, it is required to develop a general image
of maintenance, determine what is presently missing, and implement these items in a well-planned manner.
① Axial fan
As boiler capacity becomes larger, the rotating-type variable axial fan suitable for large-capacity boilers with
reduced power consumption under partial load has been widely used as a ventilating fan for power generation
equipment other than FDF, IDF, PAF, BUF, and high-temperature GRF. Control for improvement of reliability is
further required, because the structure of the rotating-type variable mechanism is complex and the number of parts
is larger than the same of the centrifugal fan.
As a result of measures taken for the improvement of reliability [1] with consideration paid to the problems
with axial FDF experienced over a period of 15 years since 1970, the employment of axial fans started, and the
problem occurrence ratio has been suppressed to its minimum. However, in view of the facts that the installation
of axial fans increased from 1985 onward when many thermal power generation plants were constructed, and that
its usage has expanded, it is desirable to carry out precise inspection of fans used for many years in order to
further secure their reliability.
② Centrifugal fan
Although the reliability of centrifugal fan has been improved, many fans have already been in use for 20 years
or longer. It is required to plan and implement measures to improve their reliability further taking into account any
aged deterioration or any change in operation from what was expected at the start of operation.
Because the operation of thermal power generation plants corresponds to the peak power generation capacity,
the number of start/stop operations has increased, which, as a result, requires the improvement of the bearing force
of impellers, bearings, and couplings.
(a) Stress change occurs at the impeller caused by the change in RPM due to start/stop of operations.
Especially with GRF, low-cycle fatigue occurs due to repeated thermal expansion caused by temperature
fluctuation. If you start the operation of GRF at room temperature, the temperature of the intake gas
rapidly changes and the vibration becomes several times larger for some time than the vibration
experienced under stable, steady operation. This is an effect of the difference in thermal expansion
caused by the temperature difference among the components of the impeller. When the temperature of
the impeller becomes stable after continuing operation in a stable gas temperature atmosphere, the
amplification of vibration gradually lowers and the operation becomes stable. In particular, when a
riveted joint is used, this phenomenon frequently appears. Therefore, if a riveted structure has been used
for the impeller, it is recommended to change it to a welded structure and remodel the connection of the
impeller to the shaft/hub to a reaming bolt connection structure from the rivet-fixed type. Because the
effect of thermal distortion concentrates on the riveted structure, non-destructive testing needs to be
carried out for the components concerned when the fan is not in use or regular inspection is carried out.
In the case of the structure of the axis–boss shrink fit, any vibration that may be caused by the decrease
in the shrink-fit margin or loosening due to the transitional difference in temperature distribution is of
concern. It may be required to increase the shrink-fit margin or change to an integrated rotor of the
axis–boss.
If the level of adherence of the mating portion of the axis–boss shrink-fit structure changes as the time
passes, that the vibration may become stronger or the torque transmission ability may drop are concerns.
Ultrasonic waves can be used to test the level of such adherence. Figure 3.2.7-1 shows the inspection
principles when a clearance is available for testing.
(b) Any fatigue damage that occurs to the face of the tooth at the gear coupling due to start/stop operations
is also a concern. Complete inspection is required. It is recommended to change to a tooth face with
improved bearing force or to a flexible coupling having no contact with the face of the tooth.
188
(c) Stress occurring at the impeller is strong. When carrying out non-destructive testing at regular
inspection, such a case is found where the portions and number of occurrences of damage increase as
time passes. In case there is concern that complete reliability may not be secured through regular
inspection or repair only, it is required to change to an impeller of a type whose generated stress has
been reduced by increasing its wall thickness or improving its welding quality.
③ Precise inspection of large-sized fan
Large-sized fans are disassembled and maintained at each regular inspection. Items subjected to precise
inspection of the respective parts of the centrifugal fan that can be implemented for such aged deterioration
phenomena as corrosion, wear, cracking, etc. are shown in Table 1. Because problems with large-sized fans can
lead to operation stop of the unit or to load limit, it is recommended to carry out full assessment at respective
regular inspection, etc.
The fan is equipped with attachment devices other than the main unit such as the lubricating device, silencer,
measuring apparatus, etc. It is required to secure the reliability of these devices as well as securing the reliability
of the main unit. For inspection of the main unit, disassembling, which requires many processes, is necessary.
Because fewer processes are required for disassembling inspection of attachment devices, it is recommended to
carry out regular maintenance once a year.
Impeller
Impeller hub
Shaft
Shaft
wave
190
boiler equipment at an adequate timing, it is very seldom that the evaporation piping is damaged by overheating
due to the thermal resistance of the scale itself.
[Metal]
Photo 3.2.8-2 is an example of a case the scale was overheated, swelled out, and opened within a very short
period of time (creep breakage in a short time); as a result, the unit was operated under such a condition that the
amount of scale adhered to the inner piping exceeded the amount for which chemical cleaning was required
(thickness 450 μm, amount of adherence 85 mg/cm²), the scale layers adhered to the inner piping were peeled
191
off and lifted, and heat conduction was blocked by the steam layers generated between the scale layers. As
countermeasures against this, it is required to capture the level of scale growth by regular pipe sampling
inspection and determine the adequate timing of chemical cleaning.
② Corrugated scale
At a plant where volatile matter treatment is undertaken as a method of treating supply water, there are many
experiences where the scale adhered to the inner evaporation piping of a furnace shows a corrugated pattern.
Especially with respect to the supercritical sliding-pressure once-through boiler, the average rate of flow in the
piping becomes higher. Therefore, scale with this corrugated appearance increases the break-through resistance of
the furnace, which may cause problems in operation. The cause of the generation of such corrugated scale has not
yet been clarified. The scale is considered to be generated under such a condition that chemical factors and fluid
dynamics factors have been combined. Namely, dissolution and deposition of the component materials in a
high-temperature, high-pressure atmosphere as chemical factors and cyclic structural change of turbulent
boundary layers as fluid dynamic factors are considered combined, whereby such corrugated scale was generated.
Photo 3.2.8-3 shows an example of the corrugated scale generated within a supercritical sliding-pressure
once-through boiler. In this case, the amount of adhered scale is not so great that chemical cleaning is required,
but problems in operation have occurred because the break-through resistance became stronger due to the shape of
such scale. As countermeasures, the scale is removed by chemical cleaning in order to reduce the break-through
resistance. Thereafter, it was clarified that the generation of such corrugated scale could be suppressed by
changing the supply water treatment to oxygen treatment, according to certain European literature ⁽⁹⁾⁽¹º⁾and the
test results of oxygen treatment verification carried out in Japan ⁽¹²⁾. This oxygen treatment method has the
advantage of a reduction in running costs, including the prevention of such corrugated scale from being generated.
Therefore, this oxygen treatment method is currently being rapidly introduced to once-through boilers in Japan.
Direction
of flow
Temperature (°C)
Fig. 3.2.8-1 Solubility curve of magnetite
Because the main ingredient in the chemical factors is magnetite and scale is generated at portions with such
high temperatures as 180℃ or more, and as one can reason by analogy from the solubility curve ⁽¹²⁾ in Fig.
3.2.8-1, the portion where scale has adhered becomes oversaturated by the degree of solution of magnetite under
such temperatures and becomes an area where fine grains of magnetite are created. As fluid dynamic factors, the
scale has adhered to the portion whose boundary layers proximate to the metal surface are thinner than other
portions in the high rate of flow in the area in which the flow path has become narrower. This indicates that the
scale adheres to such portions with high probability of the created magnetite fine grains colliding with the metal
surface. As static electrical factors, when such oxide as magnetite is submerged into water, the surface of the oxide
is charged and comes to have electrical potential (zeta potential) by certain type of static electrical phenomenon.
The intensity level of this electrical potential is related to the characteristics of the grain surface. If the grain size
becomes smaller, the characteristics of the surface become stronger. Namely, the activity of the surface becomes
especially strong immediately after the fine grains of magnetite are created. Because scale is generated to such
portions where the various factors above are combined, the scale does not always adhere to the same portions of
similar plants.
Photo 3.2.8-4 shows an example of a unit that has become uncontrollable due to adhered and solidified
magnetite scale in the high-velocity portion of the stem throttle of control valve for the spray water of the
super-heater.
Photo 3.2.8-5 shows an example of scale containing copper as its main ingredient selectively adhered and
solidified at the orifice inlet of the water drum where the flow rate has been reduced. In this case, the copper
content dissolved from the supply water heater equipped with copper alloy piping due to a failure in the supply
water treatment was brought into the boiler and selectively adhered to the orifice.
193
Photo 3.2.8-4 Example of scale adhered to control valve
Scale
Orifice
Such a failure in supply water treatment can be avoided by improving the treatment system. The adherence of
magnetite scale as mentioned above occurs even in such area where supply water treatment has been carried out
properly. Even by changing the conditions of the portion to which the scale has adhered (for example, change in
the pH, hydrazine density, etc.), only the adhering portion changes its location to some extent, and it does not lead
to any satisfactory solution. As a measure to resolve this issue of scale adherence, oxygen treatment, which has
been employed as a countermeasure against corrugated scale, is effective.
Photo 3.2.8-6 shows an example of improvement for the removal of magnetite scale adhered to the rectifying
cylinder of a high-pressure supply water heater at a power generation plant where oxygen treatment has been
adopted. Such problems as efficiency drop, vibration, etc. caused by magnetite scale adhered to the impeller of the
water supply pump have also been resolved by oxygen treatment.
194
Volatile matter treatment Oxygen treatment
Photo 3.2.8-6 Example of scale adhering to rectifying cylinder of high-pressure supply water heater
(1) Corrosion at the furnace water-wall tube of coal-fired boilers
① Corrosion
It has been known from long ago that strong corrosion occurs at the furnace wall of coal-fired boilers by flame
impingement (flames hit the waterwall piping directly in the neighborhood of the burner zone)⁾¹⁴⁾.
In such a case, it is considered that the area exposed to flames is locally placed under low oxygen partial
pressure, because a lot of unburned carbon, FeS₂, etc. are contained in the adhered ash. As shown in the chemical
formula below, FeS₂ contained in the adhered ash reacts with the Fe contained in the waterwall piping to yield
FeS. Because FeS contains more grid defects than such oxides as Fe₃O₄, the protective capability of the coat
becomes poorer, causing strong corrosion.
Recently, many cases are found such as the 2-step-type combustion process being employed for many boilers
for power generation as a measure to satisfy low NOx yield. In such a process, the area in the neighborhood of
burner zone becomes an atmosphere of low oxygen partial pressure containing H₂S. Figure 3.2.8-2 shows the
impact of air ratio on the balanced structure of gas when Datong (Chinese) coal containing 0.63% S is burned at
1300℃. When the air ratio is 0.8 or less, it is obvious that a lot of reduced contents such as H₂, CO, H₂S, etc. is
contained in the combustion gas. In particular, when such coal containing a lot of S content is used as fuel, the
H₂S density becomes higher, creating a severe corrosive environment. Corrosion of the furnace waterwall piping
caused by high-temperature sulfide becomes a critical issue. Coal combustion gas is composed of CO₂, CO, H₂O,
H₂S, COS, N₂, etc. As a result, the environment has become a family of so-called C-H-O-S. The critical factors of
corrosion are oxygen partial pressure and sulfur partial pressure in the atmosphere. In an atmosphere where the
oxygen partial pressure is high, oxidation plays a leading role in the corrosion of materials, whereas in an
atmosphere where the sulfur partial pressure is high, sulfuration plays a leading role. In an atmosphere where
oxidation is the leading player, the protective characteristic of the oxidized coat becomes excellent, resulting in a
negligible level of corrosion. On the other hand, in an atmosphere where sulfuration is the leading player, the
protective characteristic of the sulfide coat becomes remarkably poor, resulting in strong corrosion.
With respect to the corrosion occurring in an atmosphere of low oxygen partial pressure and high sulfur partial
pressure, it is considered that the reaction mentioned below is the leading player.
195
Datong coal (S content: 0.63%)
Combustion gas temperature: 1300°C
Air ratio
Fig. 3.2.8-2 Impact of air ratio on the balanced structure of combustion gas at 1300℃
This corrosion gradually grows to complete corrosion in general. At a portion where repeated thermal stress is
strong, the corrosion may grow in a groove shape in the direction of the circumference (which is called
“elephant-hide alligator-skin cracking”).
Other than the above corrosion, it has been reported that corrosion involving such vitriols as X₂SO₄, X₂S₂O₇
(X: Na or K), etc. contained in the adhered ash or pyrosulfate can occur when the SO₃ density in the combustion
gas is high ⁽¹⁵⁾. However, cases of corrosion of the waterwall piping by these alkali compounds are not reported
very frequently.
In UK where coal containing lot of Cl is used, acceleration of corrosion of waterwall piping caused by HCl
contained in the combustion gas has been reported. Because the coal currently used in Japan contains a very small
amount of Cl, no corrosion caused by HCl contained in the combustion gas has been reported to date. From the
standpoint that poor-quality coal may be used in future as fuels to be used diversify, it will be required to capture
well the influence of HCl on corrosion.
196
② Examples of corrosion and countermeasures
A cross section of corrosion of the furnace waterwall piping of a coal-fired boiler that occurred in which the
2-step combustion process has been employed in order to reduce NOx is shown in Photo 3.2.8-7. The flame side
has been evenly corroded, and the amount of corrosion was 0.15 – 2.00 mm/year.
Flame side
Photo 3.2.8-8 includes EPMA photographs of corrosive scale. The scale in the outer layer is composed of FeS,
whereas the inner layer is composed of a mixture in which Fe₃O₄ is the main content. It is typical corrosion in an
atmosphere of low oxygen containing a considerable amount of H₂S. In the neighborhood of the waterwall piping
surface where strong corrosion occurred, it is indicated that the content of H₂S in the combustion gas was 300
ppm, H₂ was 1.5%, and CO was 6.1%, and the air ratio at the moment of combustion was 1 or less.
An example of groove-shape corrosion of the waterwall piping is shown in Photo 3.2.8-9. The appearance of
the corrosion is similar to that occurring at heavy oil-fired boilers. The causes of such groove-shape corrosion
are considered to be follows. Namely, the oxidized coat on the piping surface has cracked by repeated thermal
stress arising from any combination of adhered substances to the inner piping (Fe₃O₄), condensation of air
bubbles, or local falling off of scale from the surface of the furnace piping. It is considered that corrosive gas
entered through the cracks and that the corrosion was accelerated at this gas-entered portion ⁽¹²⁾.
Considerable actions to prevent corrosion of waterwall piping are as follows:
(a) Measures to be taken in the design
(b) Selection of materials
(c) Employment of surface treatment
The most effective action is the use of coal with a lower S content. Such actions as employment of low-NOx
burners, use of fined coal to promote complete combustion, increase in the oxygen partial pressure on the piping
surface by filling boundary air (to create an air curtain along the waterwall piping) over the waterwall piping
surface, etc. are also considered effective ⁽¹⁸⁾ ⁽¹⁹⁾.
Photo 3.2.8-10 shows the EPMA observation result of the scale on the piping surface before and after filling of
boundary air. By filling of air, the scale mainly containing sulfide has changed to scale mainly containing oxide.
As measures against groove-shape corrosion, suppression of the generation of substances adhering to the inner
portions through thoroughgoing water treatment or prevention of air bubbles from condensation by employing
rifle pipes is considered effective ⁽²º⁾.
197
Na: X-ray image
Photo 3.2.8-9 Appearance of groove-shape corrosion of waterwall piping in the neighborhood of the burner
With respect to the materials, use of the double piping system composed of an outer pipe made of materials
excellent in corrosion resistance such as SUS 347 H, SUS 310 S, etc. and an inner pipe made of carbon steel is
considered ⁽²¹⁾. These materials have been already put to practical use where the materials are exposed to severe
combustion gas containing H₂S and HCl ⁽²²⁾.
For surface treatment, chromizing treatment by raising the Cr density by having Cr diffuse and penetrate is
effective for prevention of corrosion also. In addition, thermal spray coating of corrosive materials by plasma
thermal spray is effective for prevention of corrosion. Thermal spray process using 50 Cr – 50 Ni as its material
has been put to practical use.
In the case of thermal spray, however, entry of gas into the layer of the metal/thermal spray cannot be avoided.
This process has not yet been put to practical use as a permanent countermeasure.
198
O: X-ray image
Before filling
boundary air
After filling
boundary air
O: X-ray image
Photo 3.2.8-10 EPMA observation result of corrosive scale adhering to waterwall piping before and after filling
boundary air
199
3.3 Water Chemistry for the Boiler
3.3.1 Transition and Summary of Water Treatment Technology
The current water treatment technology we use in Japan derives from the U.S., introduced together with the
so-called ‘new type of thermal power’ system.
3.3.1.1 Transition of 170K-Class Water Treatment
A 170K-class unit was imported and installed at Osaka Power Plant. The boiler used was a forced circulation
type made by Combustion Engineering. Water treatment using the 170K-class unit showed a series of problems,
and the method used for water treatment changed several times.
(1) Initial Criteria for Water treatment
The initial criteria under which water quality was controlled in Osaka Power Plant are shown in Table 1.
Caustic treatment was used, in which sodium hydroxide and sodium phosphate were injected into the boiler water.
(2) Hide-Outs and Turbine Scales
Power generating efficiency decreased due to the hide-out of phosphate ions in the boiler water (and subsequent
increase in pH), and also due to deposition of sodium phosphate scales to the turbine blades (See Table 3.3.1-1).
Consequently, the downwash of the scale at the time of turbine start up contaminated the condensate water . To
eliminate the hide-out, disodium salt was used and the phosphate ion concentration was maintained at 0.2 - 2.0
ppm, which was the upper limit that Osaka Power Plant was able to manage.
However, hide-outs still existed and it was relatively difficult to control pH at an appropriate level.
1) Low Phosphate Treatment
In early 1961, a test for treating water with low phosphate treatment started. Following the results, monobasic
sodium salt was used, but since it failed to reduce the pH to the threshold limit value of GA1, i.e. 8.5 to 9.5, the
value remained to be 9.5 to 10.0.
In September 1961, Mr. Grabowski of C.E. made a presentation at the New Nagoya Power Plant and Thermal
Power Division of Kansai Electric Power Company, Inc. and showed that reducing boiler corrosion does not
necessarily require increasing pH, but the key is to protect the magnetite protection coating. He also pointed out
that Coordinated Phosphate Treatment requires the pH value to be maintained at the 9.5 to 10.0 level only (as
experienced by a boiler manufactured by C.E.) and suggested keeping the concentration of phosphate ions on the
concentration curves of trisodium salt and pH.
Table 3.3.1-1: Example of Analysis of Depositions on the Turbine Blades at Osaka Power Plant (Unit: %)
Ignition Loss SiO2 Fe2O3 Na2O CuO PO4
High Pressure Moving Blade 1st to 4.1 1.5 36.4 38.2 3.1 45.6
4th stages
* Medium Pressure Static Blade 10.0 16.0 14.5 49.0 - 23.8
1st to 4th stages
* Medium Pressure Moving Blade 20.3 23.7 15.1 58.4 6.4 0.2
3rd to 5th stages
Medium Pressure Moving Blade 24.2 23.9 19.8 49.7 1.7 0.5
6th to 8th stages
Medium Pressure Static Blade 8th 17.0 12.3 48.7 41.8 2.6 0.2
to 9th stages
Medium Pressure Static Blade 10th 10.4 2.9 61.3 40.1 3.7 0.8
stage
Medium Pressure Static Blade 11th 13.3 3.1 53.5 42.3 1.7 0.2
stage
Medium Pressure Moving Blade 22.1 9.0 34.8 63.9 1.4 0.1
13th stage
Low Pressure Static Blade 1st to 2.1 1.9 84.7 5.8 5.0 0.2
3rd stages
Low Pressure Moving Blade 2nd 2.2 1.9 54.5 6.7 7.2 0.1
stage
(Blade composition: 12 stages for High Pressure and 13 stages for Medium Pressure and 6 stages for Low Pressure)
* As shown in the original document
200
2) All volatile Treatment
Mr. Grabowski also showed a method involving the use of volatile chemicals to treat boiler water. He noted (1)
the use of volatile chemicals requires thorough monitoring of any condenser leakage and assurance of pre-boiler
system operation, (2) if a leakage occurs, phosphate salts must immediately be injected, (3) the phosphate salts
work effectively against the leakage of sea water at a concentration of 5ppm or above, below which they are
ineffective and (4) after reaching the cationic conductivity of 0.5µS/cm, the phosphate salt must be kept at 10 to
15 ppm.
He also instructed that the cationic conductivity of boiler water be maintained at 2 to 3µS/cm during normal
operation and to feedwater at a pH of 8.8 to 9.2.
Ratio of silica contained in steam to that in water (%)
Water Quality
Requirements
Average pH Silica (ppm.)
Pressure (psig)
Fig. 3.3.1-1: Impact of Pressure, pH and Concentration of Silica in Water to the Ratio of Silica under the Steam
Generation Volume of 5lb/h and in Static Condition
201
Acceptable silica concentration in boiler water in
order to retain silica concentration in steam to 0.02
ppm or below
Silica (ppm.)
All volatile
treatment: pH:
approx. 9.0
Pressure (psig)
Fig. 3.3.1-3: Acceptable Silica Concentration in Boiler Water (by C.E.)
(3) Shift of Criteria for Condensate water and Make-up water
The reference pH value shown by Gilbert for condensate water and make-up water at Osaka Power Plant was
8.6 to 8.8. The value depends on the volume of ammonia generated by the decomposition of hydrazine. However,
an increase of hydrazine injection caused a surge of pH to nearly 9.0. Gilbert explained that ammonia would
attack the copper alloy condenser tube if the pH value of ACD was high. In this case, the value should be kept to
8.8. However, the company also explained that if the pH of ACD were below 9.8, the pH of the condensed and
make-up water might be around 8.6 to 9.0.
So as criteria for pH and hydrazine concentrations, the ceiling was set to 0.05 ppm for hydrazine and 8.9 for pH
respectively, so that they can be maintained at these levels, even when there is a load variation. As it is difficult to
limit the hydrazine concentration to 0.01 ppm or below in a stable manner, and as there is concern regarding the
accuracy of the analysis, the lower limit of hydrazine concentration was set as 0.01 ppm.
(4) Silica and Silica Purge
In order to avoid bad influence to a turbine by silica scales, it is necessary to limit the volume of silica
contained in steam. As for the limit, the following three reports were issued in the U.S.:
1) Experience shows silica in steam should be contained to 0.03 ppm or below to avoid any scales being
deposited to the turbine.
2) No deposits was found in the low- and medium-pressure turbine blades of a turbine with 150MW, 170k and
550°C when the silica concentration in the high pressure turbine exhaust was retained to approx. 0.01 to
0.02 ppm.
3) Experience shows no silica is deposited on turbine blades when the silica concentration is kept at 0.02 ppm or below.
202
Table 3.3.1-2: Maximum Permissible Total Soluble Solid Material in Steam (Unit: ppb)
Permissible Permissible Permissible
Material Concentration for Concentration for Concentration for
Continuous Operation Conditioned Operation Intermittent Operation
NaCl 400 2000 4000
Na2SO4 400 2000 4500
Na3PO4 60 150 300
NaOH 30 60 150
SiO2 8 20 45
Total 898 4230 8995
Table 3.3.1-3: Example of Measurement for Drum Carry-Over in the U.S.
Name of Power Plant Chestexfield Ashtabula
Load 170 MW
Drum Pressure 2600 psig 2500 psig
Na Concentration of Boiler Water 7.5 ppm 10.6 ppm
Concentration in Steam 0.0021 ppm 0.0029 ppm
Carry-Over Ratio 0.028% 0.027%
NaCl Concentration of Boiler Water 9.4 ppm 15.3 ppm
Maximum Carry-Over Ratio 0.057% 0.047%
Referring to the above reports, the concentration of silica was set to 0.02 ppm or below.
The tolerance of silica concentration in boiler water depends on the ratio of silica distribution in saturated steam.
It also depends on pressure and pH, as shown in Fig. 3.3.1-1. Based on the distribution ratio, Fig. 3.3.1-2 is drawn
and C.E used Fig. 3.3.1-3.
In Fig. 3.3.1-2, the silica concentration is 0.18 to 0.19 ppm under the pressure of 186 to 188k and a pH of 7.8 to
9. From these data, the silica concentration was set as 0.2 ppm.
As the silica concentration in boiler water tends to rise when the boiler starts operation, due to the silica scale
deposited on the turbine low-pressure blades being washed away by wet steam, a silica purge must be
implemented to raise pressure by blowing the boiler, while ensuring the silica concentration is limited to within
the designated value. This is the main cause of delays and increased load when starting the drum type boiler.
Therefore, looser values were set, as shown in Fig. 3.3.1-4, for the concentration of silica when starting a boiler.
The silica-washing device installed in a drum manufactured by Babcock-Hitachi K.K. showed a remarkable
ability to reduce the silica concentration in steam, doubling the permissible concentration of silica in the boiler.
(5) Total Soluble Solid Materials
As for the total soluble solid materials, the following reports were issued in the U.S.:
1) Fig.3.3.1-2 shows the permissible concentration for continuous operation (the maximum concentration that
does not cause significant silica deposit after operating a turbine for 8,000 hours), the permissible
concentration for conditioned operation (the maximum concentration after repeated stopping and restarting
or under such operation conditions as variable pressure operation) and the permissible concentration for
intermittent operation (the maximum concentration that does not cause any silica deposits for a relatively
short turbine operating period). The permissible concentration for continuous operation is approx. 1 ppm.
2) No significant silica deposits were observed in the concentration range of 0.1 to 0.2 ppm.
3) In order to operate a turbine without any washing for an extended period, the silica concentration must be
controlled to 0.05 ppm or below.
Experience at Himeji No. 2 Power Plant showed that deposits were rarely seen when a turbine was operated
with cationic conductivity of 0.3µS or below. This corresponds to a silica concentration of 0.05 ppm.
Based on the above, the cationic conductivity and the silica concentration were determined as 0.3K-µS/cm or
below and 0.05 ppm or below, respectively.
In order to determine the limit value for the total solid materials in the boiler water, the carry-over ratio of the
drum should be considered. With this in mind, the following data is issued:
1) The design value is 0.25%.
2) The value measured in the U.S. is 0.05% or so, as shown in Table 3.3.1-3.
3) The value measured in Himeji No. 3 Power Plant was approx. 0.15%.
Based on the above, the value was determined as 0.2%, taking safety into consideration, and the total solid
materials in boiler water was set as 25 ppm.
As the measurement of water quality under the all volatile treatment is 5K-µS/cm, or 10K/µS/cm at worst, the
total solid materials in boiler water was determined as 10 ppm.
203
First stage low temperature reheated steam
Second stage low temperature reheated steam
Ignition Fourth steam
Combined Normal values
feeding
Time (h)
Fig. 3.3.1-5: Trend of Hydrogen Concentration
after chemical cleaning
Permittivity of
Cation-Exchange Resin
Time
Condensate
t Exit of WW
Entrance of ECO
Second stage low temperature
reheated steam
KC-floc used
204
(6) Hydrogen
As for hydrogen, it only indicates the corrosion condition of a tube and no measures can be taken based on it .
The generation of hydrogen can be determined as stable, because it remains commensurate with the surface
area, regardless of the volume of steam generated. Thus, it seems normal that the hydrogen concentration doubles
when the flow decreases by half.
As seen in the example where the hydrogen concentration is 2 to 4 ppb under stable operation, the chemical
reaction of iron and water continues to a certain extent, even under stable operation. This means the magnetite
coating undergoes a cycle of damage and recovery to a certain extent.
Increased hydrogen generation tells that the following events are happening:
1) The magnetite coating incurs significant damage. : E.g.: After chemical cleaning, the magnetite coating is
removed and thus hydrogen increases, returning to the normal level as the coating is formed (Fig. 3.3.1-5).
2) A new steel surface has appeared. : E.g.: Iron powder is generated by the flying apart of turbine blade; a
new metal surface appears on it, on which a chemical reaction progresses rapidly (Fig. 3.3.1-6).
3) The metal temperature has surged abnormally. : There is a report that the hydrogen concentration increased
by about 10 ppb when a reheating pipe caused creep damage for a relatively short period.
4) Organic materials (sugars) inputted have been decomposed (Fig. 3.3.1-7): There is a report that fine resin
leaked out from a condensate demineralization tower when water was introduced into it immediately after
replenishing the resin.
(7) Malfunctioning of Boilers in the U.S.
Table 3.3.1-4 indicates the result of investigations by the American Society of Mechanical Engineers (ASME)
on 116 boilers in the U.S. from 1950 to 1959. As stated in the table, 40% of boiler showed some pipe damage,
while 28% of boilers caused crater-shaped corrosion, which is considered alkali corrosion. Fig. 3.3.1-8 shows the
relationship between crater-shaped corrosion and hydroxy-ions, expressly showing how the concentration of the
latter may decline as pressure goes up.
205
Table 3.3.1-4: Outline of 116 Boilers in Use
No. of Boiler % No. of Boiler %
Manufacturer Deaeration unit
A 42 36 Used 89 77
B 49 42 Not used 27 23
C 14 12 Final treatment of makeup
D 8 7 water
E 3 3 Deionizer is used. 50 43
Pressure (kg/cm2) Steam evaporator is used. 66 57
63 or below 13 11 Boiler water treatment
64-91 21 18 Sodium sulfite 80 69
92-126 53 46 Hydrazine 41 35
127-155 26 22 Caustic soda 81 70
156 or above 3 3 Phosphate 111 96
Capacity Potassium salt 3 3
90 or above 6 5 Organics 13 11
90-225 33 28 Condensate water treatment
225-337 26 23 Morpholine 76 65
337-450 28 24 Cyclohexylamine 12 10
450 or above 23 20 Ammonia 12 10
Overheat Temperature (°C) Problems
427 or below 0 0 No corrosion losses 70 60
427-496 15 13 observed to pipes
496-552 80 69 Crater-type corrosions 32 28
552 or above 21 18 (20 to 23% are of
fluidity
Reheating Temperature (°C) hindrance.)
496 or below 0 0 Burnout due to overheat 5 4
496-552 68 59 Bubbles observed 2 2
552 or below 3 2 Overheat at the top of 1 1
No reheating 46 39 pipes
Fuel Orifice 13 11
Fine charcoal powder 72 62 Others
Gas 36 31 Pitting corrosion of 2 2
Oil 4 3.5 header
Others 4 3.5 Pitting corrosion of 3 2
(chain grate-fed charcoal and coal)
suspending metals
Year of Operation Corrosion of separation 2 2
Before 1950 7 6 tube
1950 4 3 Attachment to header 5 4
1951 5 4 Corrosion of feed heater 13 11
1952 7 6 Turbine attachments 9 8
1953 18 16 (Water-soluble
1954 28 24 9)
1955 18 16 Carry-over of silica 3 3
1956 11 9 Acid washing
1957 7 6 With acid washing 34 29
1958 8 7 No acid washing 82 71
1959 3 3 With initial acid washing 45
Economizer No initial acid washing 37
Used 101 87 Total number of acid
Not used 15 13 washings
Once 44
(Initial acid
washing 22)
Twice 14
(Initial acid
washing 7)
Three times 21
(Initial acid
washing 13)
Four times 2
(Initial acid
washing 2)
Five times 1
(Initial acid
washing 1)
For users, chemical cleaning to prevent any damage, for manufactures, designs to avoid hot spots or fluidity
hindrances, for consultants, the removal of dissolved oxygen, carbon dioxide and sulfur dioxide from the
pre-boiler, curtailment of dissolving iron and copper and research into controlling the pH level are requested.
206
Temperature of Boiler Water and Pipe
Concentration
Mother Water of
Boiler Water
Temperature
Concentrated
boundary Film
of Cases
Number
Example
Year
208
Table 3.3.1-5: pH Control Methods of the Pressure Boiler of 130kg/cm2 or above by C.E.
How to Adjust pH No. of Boilers
(1) Caustic Based pH10.5 to 11.0
37
(Caustic alkali and phosphate ions are used.)
(2) Low Caustic Control pH10.0 to 10.5
8
(Same as above)
(3) Cordinated Phosphate – pH Control pH10.0 to 10.5
29
(Coordinated phosphate treatment is used and caustic alkali is not used.)
(4) All volatile treatment: pH 8.5-9.0
21
(Hydrazine and ammonia treatment is used and no solid chemicals are used.)
Approx. 10%
209
Total
170K Class
140K Class
Year
Fig. 3.3.1-12: Trend of High Pressure Boilers
Percentage in the Entire Treatments %
Sodium
Sodium phosphate
hydrate
Potassium salt
treatment
Year
Fig. 3.3.1-13: Trend of Boiler Water Treatment
Dick revealed that all volatile treatment is not a panacea against water damage accidents, because there were
reports of significant water wall tube trouble occurring in some boilers subjected to all volatile treatment.
Decker disagreed with the use of all volatile treatment on drum type boilers, stating that such treatment was
rarely beneficial to them.
Every few years, an accident involving increased differential pressure to a forced circulation boiler with all
volatile treatment happens due to the attachment of scales to the orifice installed at the inlet of water pipes. This is
likely to occur just after chemical cleaning and the likelihood of such incident is based on how the initial
crystallization occurs. The scale present consists of mainly magnetite. As anti-scale measures, (i) removal and
cleaning, (ii) modification of the orifice shape, (iii) change of the orifice material to soft steel, and low phosphate
treatment were carried out.
Subsequently in 1970, of four heavy oil boilers of virtually the same design, two treated by volatile chemicals
were involved in an accident, while another, although not involved in an accident, was affected by a zinc scale
attachments on a considerable scale. On the other hand, boilers subjected to low phosphate treatment showed no
such zinc scale deposits. It was considered that the use of low phosphate treatment not only stops zinc deposits but
also decomposes part of the zinc oxide deposits into zinc phosphate.
Thus, conventional method of all volatile treatment was switched to phosphate treatment at boilers used mainly
by Electric Power Development Co. Ltd. Table 3.3.1-6 shows a comparison performance comparison featuring the
scale generation behaviors of 23 boilers before and after changing the mode of water treatment. As the table
shows, 4 units showed that phosphate treatment worked well in reducing the generation of scales. No unit showed
an increase of scale when phosphate treatment was used in lieu of all volatile treatment. Even taking into
consideration the change in operating conditions, phosphate treatment showed a reduction of scale generation. It
was therefore considered that phosphate treatment was applicable for restricting scale deposits in the generating
tubes of a boiler.
210
Table 3.3.1-6: Survey on Boilers whose Water Treatment Method was Switched from
All volatile treatment to Low Phosphate Treatment
Start of When Phosphate Materials for the Condenser Materials for the Feed Heater
Unit Capacity Furnace Circulation Operation Treatment was
No. (MW) Type Method (Year/ Started Condensate water Part Air Cooling Part Low Pressure Part High Pressure Part
Month) (Year/Month)
36 375 Single Natural 47.11 53.3 Aluminum brass Nickel-plated Aluminum brass Monel metal
aluminum brass
65 156 Divided Natural 39.8 48.1 Aluminum brass Cupronickel Copper arsenate Monel metal
66 156 Divided Natural 41.2 45.3 Aluminum brass Cupronickel Copper arsenate Monel metal
67 350 Divided Natural 44.1 51.5 Aluminum brass Monel metal Aluminum brass Carbon steel
70 156 Divided Natural 39.6 53.2 (50.6P→A) Aluminum brass Cupronickel Copper arsenate Monel metal
78 156 Divided Natural 48.4 53.5 Aluminum brass Titanium Aluminum brass Alloy steel
Carbon steel
86 250 Divided Natural 42.7 49.4 Aluminum brass Cupronickel Aluminum brass Alloy steel
87 250 Divided Forced 43.7 52.6 Aluminum brass Nickel-plated Aluminum brass Alloy steel
aluminum brass
88 250 Divided Forced 44.1 52.2 Aluminum brass Nickel-plated Aluminum brass Alloy steel
aluminum brass
89 265 Divided Natural 42.5 47.5 Aluminum brass Titanium Copper arsenate Carbon steel
90 265 Divided Natural 44.9 50.10 Aluminum brass Titanium Copper arsenate Carbon steel
106 350 Divided Natural 47.2 54.1 BKCB Titanium Aluminum brass Carbon steel
108 265 Divided Forced 35.10 54.11 Aluminum brass Nickel-plated Copper arsenate Monel metal
aluminum brass
109 265 Divided Forced 37.9 54.10 Aluminum brass Titanium Copper arsenate Monel metal
112 350 Divided Forced 41.7 53.6 Aluminum brass Titanium Copper arsenate Alloy steel
Titanium
113 350 Divided Natural 42.1 55.12 Aluminum brass Titanium Copper arsenate Alloy steel
118 350 Divided Forced 43.1 53.7 Aluminum brass Aluminum brass Aluminum brass Alloy steel
Cupronickel
122 250 Single Forced 45.6 54.1 Aluminum brass Cupronickel Aluminum brass Alloy steel
147 350 Divided Natural 44.9 53.6 Aluminum brass Titanium Aluminum brass Alloy steel
Carbon steel
148 350 Divided Natural 45.1 55.12 Aluminum brass Titanium Aluminum brass Carbon steel
168 250 Divided Natural 46.1 51.3 Aluminum brass Cupronickel Aluminum brass Carbon steel
169 350 Single Forced 48.1 53.12 Aluminum brass Cupronickel Aluminum brass Carbon steel
181 400 Single Forced 52.9 56.3 Aluminum brass Titanium Aluminum brass Carbon steel
Table 3.3.1-7: Corrosion Damage Reported in the U.S. on Drum Boilers (125k Class or above)
New damage Number of units in Ratio of annual
Periods
reported operation damage occurred
1955-1960 48 219 3.6%
1961-1965 39 385 2.0
1966-1970 27 481 1.1
* Corrosion newly discovered
Table 3.3.1-8: Damages to Boilers by Pressure and by the Water Treatment Method
Pressure 125k Class 140k Class 170k Class Total
All volatile treatment 5 7 11 23
Sodium Phosphate Treatment 12 3 8 23
Sodium Hydroxide Treatment 41 18 4 63
Potassium Salt Treatment 5 5 - 10
Total 63 33 23 119
The No. 2 Boiler of the Himeji No. 2 Power Plant was imported from the U.S. and commenced comercial
operation in 1964. Table 3.3.1-9 shows the water quality standards, set based on actual operation performance.
This boiler uses hydrazine and ammonia injected into the outlet of its condensate purification equipment and
ammonia into the outlet of its deaeration unit.
(1) Condensate purification equipment
Condensate purification equipment normally consists of a mixed bed condensate demineralization tower and
filters placed in front of it. Some act as a polisher of supplementary feed.
The following three major objectives are associated with the use of condensate purification equipment:
1) To prevent damage to the entire system due to the leakage of a condenser
2) To purify the supplementary feed
3) To remove corrosion products from the feed water system
The secondary objectives include:
1) to purify various drain water before it enters into the system, and
2) to purify the system during the initial start-up and shutdown operations.
Contamination of ion-exchange resin by metal oxides and pressure loss of the condensate demineralization
tower impose significant impacts to the system when a high-speed ion exchange takes place. Due to this, a filter is
installed just before the tower to remove them and prevent the ion-exchange resin from deterioration.
As for appropriate materials to use for the filter, cellulose, diatomite, leaf-type and other fine pore filters are
recommended.
As for the condensate water condensate demineralization tower, although the impact of dissolved resin to the
tower has not yet been clearly identified, some say that the use of a filter, which puts after the demineralization
tower, can eliminate leakage from the tower. Himeji No. 2 Power Plant employs a combination of filters made by
United Filters, Inc. and Permutite Company. The label said the design conductivity was 0.2µS/cm, and that design
silica, iron and copper concentrations were 7 ppb, 5 ppb and 5 ppb respectively, although these are not guaranteed
values.
The imported item of Himeji No. 2 Power Plant uses a horizontal leaf type pre-coat filter and Solka floc
212
BW-100 and -40 were used at a ratio of 1 to 1 as filtering agents. The agents heavily leaked out, were deposited on
the resin surface of the condensate demineralization tower caused pressure loss of the tower. The reasons for the
leakage were attributed to leaf-end gaps, the distance of leaf hubs, the non-parallel arrangement of the same,
variations in the water flow, an excessive design flow rate and the screen structure. The pressure loss exceeded the
design value, after pre-coating, it was attributable to the excessive flow rate and an overly small shaft and shaft
hole diameter. To eliminate the pressure loss, the system underwent renovation, but the loss still exceeded the
design value. So, other filter unit was added.
It is believed that the black carbon precipitated to the boiler tube when the filtering agent leaked in large
amount.
The condensate demineralization tower showed resin leakage, which was attributable to the gap of the disc
strainers, the distances between a disc strainer and the strainer plate and between the strainer plate and a bottom
plate.
In addition, sending resin to the regeneration tank led to massive amounts of residual resin accumulating at the
bottom of the tower, resulting in an insufficient regeneration process and imbalances between the cation and anion
resins. This was due to a structural defect at the bottom of the tower.
As the pressure loss of the condensate demineralization tower became abnormally high, resin with less than 60
mesh was filtrated using a filter (Permatite Q and S-1). The total annual fraction ratio came to approx. 45%, with
the ratio of damaged anion resin particularly high. As for the cause of the fractured resin, this was found to be
attributable to the relatively high design flow rate of 119m/h (51). Due to such experiences, a flow rate of 80m/h
was recommended.
However, despite such measures, the water purity showed no improvement. Even after investigation by a
Japanese condensate demineralizer manufacturer, no causes were identified. So, the staff was so desperate for help
that they used a sieve to remove small resins, whereupon the water purity showed improvement.
213
(2) Cleanup
(Inlet of an economizer in front of a
boiler unit of Himeji No. 2 Power Plant)
Lowest Range
Highest Range
Start of switchover to a high
Time
pressure heater (second time)
B-Line Feed Water
* Sampling Time
[No. 4 Unit of Himeji No. 2] [No. 2 Unit of Takasago] [No. 4 Unit of Kainan]
1973.6 1973.5 2: Furnace fluid: 120°C 1973.8
1: After boiler inspection 1: Acceptance of cleanup before 3: Furnace fluid: 190°C 1: Immediately before the ignition of the boiler
2: Cleanup at 117°C the ignition of the boiler 4: Furnace fluid: 300°C 2: Inlet of Primary SH: 200°C
3: Inlet of Primary SH: 350°C
*2 The upper line of each column shows the concentration of iron collected by 0.45µm, 0.22µm *3 The iron concentration values are rounded
and 0.025µm filters, while the bottom line shows the percentage of iron oxides of more than off to the nearest whole number.
0.45µm, .22µm and 0.025µm in size relatively to the total iron.
3.3.1.3 Emergence of a Supercritical Pressure Unit
The first supercritical pressure unit commenced commercial operation at Anegasaki Power Plant in Chiba
Prefecture in December 1967, followed by the No. 4 unit in the Himeji No. 2 Power Plant in March 1968. In the
U.S, the first supercritical pressure unit to commence commercial operation was the 315k Class Philio No. 6 unit
(125MW) in 1957. Based on the experience of this unit, a 246k Class, 538°C unit was developed after 1964, and
in 1966, such units occupied almost half of all power generation capacities developed for steam-power generation.
215
As in the U.S. a supercritical pressure unit started operation without identifying the movement of impurities in
water under supercritical condition, many troubles of copper scales to a high pressure turbine was reported due to
the copper dissolved in steam. The troubles became a synonym of a trouble peculiar to supercritical pressure unit,
that had not been experienced in subcritical pressure units. For example, Avon No. 8 unit experienced a copper
scale deposit of 1.5 to 2.3mm in thickness and 5.5 lbs. in weight during its three-year operation, and the load of
250 MW was decreased to 216 MW.
Subsequently came the introduction of a supercritical pressure unit aiming to meet the increased power demand
during periods of high economic growth. As the new unit handles supercritical pressure, completely different from
subcritical pressure, the latest water treatment system was employed to handle the latest water treatment
technology at that time.
There remained some challenges to be overcome in water treatment after the introduction of a supercritical
pressure unit. The following are the experiences of the No. 4 unit in the Himeji No. 2 Power Plant.
(1) Copper and Condensate purification equipment
As explained above, the concentration of copper must be minimized, as it deposits on turbine blades. Referring
to experiences in the U.S, 2 ppb was determined as a target for the copper concentration.
To eliminate copper, there are two methods; namely removing copper alloys from plant and using condensate
purification equipment.
For the former, steel pipes were used for the feedwater heater in lieu of copper alloy pipes. The No. 4 unit of
Himeji No. 2 Power Plant only used copper alloy for its low-pressure heater No. 1 and 2.
There was no alternative to the use of aluminum brass and copper dissolved from a condenser can be removed
by condensate purification equipment. However the condensate purification equipment manufactured by Graver
and installed as the No.4 unit of Himeji No. 2 Power Plant met the guaranteed value of 0.3µS for electrical
conductivity, while the iron, copper and total dissolved solid material concentrations of 10 ppb, 3 ppb and 35 ppb
respectively were only the target values. The condensate demineralizer used was an external regeneration system.
With this in mind, the criteria for the copper concentration of the No. 4 unit of Himeji No. 2 Power Plant was
set to 3 ppb, although the actual concentration could be contained at almost 2 ppb. All the units installed in the
Power Plant thereafter used steel pipes for all feed heaters and the criteria was changed to 2 ppb, which was
successfully met thereafter.
Temperature
Fluid Temperature (°F)
Iron Deposition Volume (g/ft2)
Deposition
Normal Operation
Ratio of Removal (%)
(0.3m/s)
Magnetite
Total iron
Heat up of a plant
Iron (pbb)
(Source: Condensate water of
the Kiel Power Plant)
Fig. 3.3.1-16: Performance of an Electromagnetic Filter
Curtailment of Decreasing
pressure surge at the
outlet of a feed water
power Prolonged chemical cleaning
pump consumption of intervals
the feed water
pumps
Enhanced reliability Enhanced cost
performance
219
Fig. 3.3.1-17: Expected Effects of the Oxygen Treatment Method
220
(Legend)
(Legend)
Oxygen Oxygen
(Legend)
During the research
period
Differential Pressure (kg/cm2)
Regular Inspection
(Chemical cleaning)
Regular
Inspection Regular
Inspection
Number of Months
Chemical Start of CWT
cleaning
Fig. 3.3.1-20: Shift of Boiler Differential Pressure
1) When Converting to CWT
Just after the conversion to CWT, the iron concentration surged by more than 8 times or 24µg/l at the inlet of an
economizer, compared to AVT. This transit phenomenon was also seen in copper concentration (tripled to 2µg/l).
Both phenomena, however, disappeared within a few weeks.
The reason for this may be attributable to the fact that protection layers were not formed smoothly because of
decreasing pH (AVT9.6→CWT8.5) and the fact that the injection of oxygen was performed simultaneously when
the CWT was first started. In future, first oxygen should be injected to monitor the behaviors of dissolved oxygen
(DO) and iron while reducing pH step by step.
2) Long-Term Running (pH: 8.5, DO: 100µg/l)
As shown in Fig. 3.3.1-18, compared to AVT, the iron concentration doubled to 8.8µg/l at the outlet of a
condensate pump before injecting oxygen, due to the decreased pH, while after injecting oxygen, it reduced to
between a third and a half (3.1µg/l→1.6µg/l at the inlet of an economizer). The CWT thus seems relatively
effective in reducing the iron concentration of feed water and the volume of iron fed into boilers.
3) Relationship between pH and DO
As shown in Fig. 3.3.1-19, at the outlet of a condensate pump, as the pH increased, the iron concentration
tended to decrease, with a level equal or slightly higher than AVT. The same trend was observed in low pressure
feed heater drain, although no significant effects were observed in other systems.
There were also no significant relationships observed between pH and DO.
b. Copper Concentration
The copper concentration in CWT was at the same level as AVT, i.e. 0.6µg/l. No significant relationships were
observed between pH and DO as well.
(2) Differential Pressure of Units
a. Differential Pressure of Boilers
The boiler differential pressure refers to the difference in the pressure lost between the inlet of an economizer to
221
a steam separation drain tank.
As shown in Fig. 3.3.1-20, the pressure surged by approx. 8kg/cm2 in 1.5 months for AVT, before the start of
CWT. It then became a decrease one month after the start of the CWT, whereas in 9 months, the differential
pressure had decreased to the same level as that after chemical cleaning was applied to the unit (30kg/cm2). The
trend continued thereafter, before ultimately reaching differential pressure equivalent to that at the commissioning
of the unit, i.e. 27.5kg/cm2).
Compared to AVT, the differential pressure showed a significant decrease to approx. 15 kg/cm2, which was the
same level as that of a unit 15 months after chemical washing.
Due to such reduced differential pressure of boilers and other factors, the BFP outlet pressure was reduced. The
volume of steam required for operating the BFP was reduced by 6.7 t/h for low pressure steam and 5.3 t/h for high
pressure steam, compared to AVT, as shown in Table 3.3.1-12.
This effectively shows that CWT is relatively effective in reducing the differential pressure of boilers and the
BFP power loss.
Table 3.3.1-12: Comparison of Steam Volume for Operating BFP (Unit: t/h)
1 AVT 2 CWT 1-2
Low pressure steam 125.3 118.6 6.7
High pressure steam 9.2 3.9 5.3
Note 1: For AVT, the figures are the mean values from Jan. 1987 to April 1990.
Note 2: For CWT. The figures are the mean values from Jan. 1991 to Jan. 1992.
(Legend)
The unit used for this
research
No. 4 unit of the Ulsan
Thermal Power Plant
Generation Speed (mg/cm2, 1,000h)
(2.5 years)
Fig. 3.3.1-22: Water Pipe Scale Generation Speed of the Unit used for This Research and
the No. 4 Unit of the Ulsan Thermal Power Plant
(Legend)
Generation Speed (mg/cm2, 1,000h)
223
(iii) Surface Conditions of Scale
As Picture 3.3.1-1 shows, for AVT, the scale was in a waveform of crystals of 10 to 20 µm in diameter.
Around a year after the switchover to CWT, the surface conditions of the scale changed into a shape of fine
powders of several µm in diameter, and no waveform shape scales were identified. After approx. 2.5 years,
further progress was made in terms of miniaturization of the fine powder diameter.
224
Resin Resin
Scale Scale
Pipe Pipe
Wall Wall
225
was concern regarding corrosion in sections containing stagnant water.
In order to observe and assess the corrosion, a drain pipe close to the inlet of an economizer and close to the
inlet pipe of a horizontally-set superheater header were chosen as two representative locations where water tends
to be stagnant and oxygen is hardly supplied. Consequently, no significant differences emerged in the corrosion
performance of CWT and AVT.
(Legend)
226
An investigation was conducted on seven kinds of valves including the main steam stop valve. As a result, there
was no significant difference when compared to AVT generally.
The maximum depth of erosion to a sub-valve of a main steam stop valve was 4 to 5 mm, which is equivalent to
that observed in AVT.
(c) Instrumentation and Control Valves
A series of investigations was conducted to 9 types of valves, including BFP overheat prevention valves.
Consequently, the drain control valve attached to a high pressure feed water valve No. 3 showed a significant
decrease in the volume of scales (while in AVT, valve sticks were observed due to the deposition of scales), of
which the thickness was one fifth or below compared to AVT (0.6 to 3.0 mm → 0 to 0.5mm). The scale was soft
and easily removed and maintained.
As for corrosion and erosion performances, no significant changes emerged between AVT and CWT except for
erosion, as explained in 3.3.3.1.6-(3)-d ‘Parts Using Stellite Materials’ observed on the BFP overheat prevention
valves.
Picture 3.3.1-3: Scales Deposited on the Flow Rectifying Tower of the High Pressure Feed Heater
Good
Bad
227
(d) High Pressure Water Feed Heater
The color of scales for both the inner water chamber and inner heating pipe, as well as the flow rectifying tower,
changed from black magnetite to red-brown hematite, while X-ray analysis also confirmed an increase in hematite
materials.
Meanwhile, the volume of scales was also subject to decrease. As shown in Picture 3.3.1-3, the hardened scales
that had been removed during regular AVT inspection were rarely observed. As shown in Fig. 3.3.1-25, the
volume of scales in CWT was one tenth or below (1,520→150g/year).
Due to the decreased scale, the differential pressure of a high pressure feed heater was decreased and, as shown
in Fig. 3.3.1-25, the heat transfer performance (TD: Temperature Difference at the End Parts) was increased by 0.3
to 0.5°C, compared to AVT.
As for the corrosion and erosion performances, no significant differences were observed between AVT and
CWT and a similar trend was observed for other types of heat exchangers (condensers and deaeration units).
(e) BFP
A series of investigations was conducted on a rotator and strainer. As shown in Fig. 3.3.1-24, the volume of
scales attached to the rotator was found to have decreased to approx. one fifth of that to AVT (460→100g/year x
unit) and no waveform scales, as observed in AVT, were seen around the CWT periphery. As for the strainer, the
scales were around one sixth that of AVT (250→40g/year x unit).
Regarding corrosion and erosion, as shown in Fig. 3.3.1-26, the wear volume of the chrome plating layer of the
driving part of the rotator showed an increase compared to that of AVT (0 to 0.06mm→0.02 to 0.35mm in terms
of the maximum volume at each stage). It was presumed that feed water containing oxygen had slipped into the
micro pin holes and micro cracks, causing corrosions in the gap between the base materials and their plating
layers and leading to removal of the layer.
In order to reverse the situation, the following corrosion tests were carried out using an actual unit and chrome
plating combined by electroless nickel plating was found to be effective.
[Test Procedures]
Location: Suction strainer of BFP
Materials: Base material (13 Cr)
Cr plating
Composite electroless nickel plating
Cr plating + electroless nickel plating
Thermal spraying of oxidized Cr
Periods: July 1992 to Jan. 1993 (for 6 months)
Carbonized Cr-W
Co-Cr-W crystals
229
e. Cautions in Operations
(1) How to Operate a Deaeration Unit
Based on experiences in Germany, the vent valve of a deaeration unit was kept closed from the onset of
switchover to CWT. This, however, caused an abnormal surge in the DO concentration (600 ppb or above) at the
outlet of the deaeration unit during the unit operation at low load. This was because, due to the closure of the vent
valve, the high concentration of oxygen, which was deaerated during high load operation, was stagnant in the
upper part of the unit, before expanding in volume, being scattered away and then redissolved in water due to the
decreased pressure inside the unit.
To reverse this situation, the vent valve was left open. This, however, caused deaeration and discharge of DO,
making the environment the same as AVT with low pH and causing the iron concentration at the outlet of the
deaeration unit to surge.
Due to such experiences, the vent valve was again left closed, and only reopened when the DO concentration
surged (intermittent operation).
(2) Increased Differential Pressure of the Electromagnetic Filter (EMF)
Once the use of CWF had commenced, the initial differential pressure after backwashing and regeneration of an
EMF occurred and its post-regeneration operation life was shortened (in 7 months, the operation life was
shortened to one tenth (or 2 days) compared to that used in AVT). The reasons for this are believed to include: (i)
the fact that CWT tends to have higher iron loads than AVT, (ii) an increase in fine particles of FeOOH (the
number of FeOOH particles of 1 µm tripled or quadruplicated), which split into the depth of the element and (iii)
the fact that needle-shaped iron crystals reinforced the iron deposit layer, which could not be removed by a
backwash and regeneration process.
To reverse such conditions, jet washing of elements was employed and the elements were replaced with new
ones.
In order to implement permanent measures, the following items are subject to examination: -
(a) Decreasing iron loads at the inlet of an EMF (pH to be increased to 9.0 : effectiveness confirmed)
(b) Improvement of the regeneration methods
(c) Improvement of elements
f. How to Start and Stop the Unit
For several months after the use of CWT, the unit cleanup time tended to be longer than for AVT, due to
unstable hematite protection layers and for other reasons. This was successfully solved through measures to
improve the cleanup process, such as stabilization of the protective layers, lapping of the boiler and pre-boiler
processes and an improved flow rate and numbers of swinging, as shown in Fig. 3.3.1-14.
Water
Treatment Hydrazine Cleanup Time (h)
Let-up
Method under Injected or
Time (h)
Normal not -10 -8 -6 -4 -2 0
Operation
Deaeration
AVT 24.5 Injected Unit Pre-boiler Boiler
Circulation of Condensate Deaeration
CWT 31.0 Injected Pre-boiler and Boiler
water Unit
Circulation of
CWT 29.0 Not injected Pre-boiler and Boiler
Deaeration Unit
230
Table 3.3.1-15: Optimized CWT Operation Method
Item Controlled Values and Operation Method
Normal Operation
Item Stop
DO (µg/l) *50 to 100
pH *8.5 to 9.0
Cationic conductivity (µS/cm) 0.2 or below
* All control values referred to above are for feed water at the inlet of an economizer.
Start-up and Stop
Item Startup Stop
Water Treatment Conventional method (AVT) Conventional method (AVT)
Method
AVT x Minimum loads or above, and x At least 3 hours before the planned
↑↓ x Electric conductivity of 0.2µS/cm or time for disassembly of the unit
CWT below Reason: All water must be
Switchover Period circulated once during the period
between the switchover from AVT
and before shutdown of the plant.
Storage Conventional method (AVT)
Leakage of seawater When seawater leakage happens, CWT must be promptly switched over to AVT.
Deaeration unit CWT: The vent valve of a deaeration unit must be subject to intermittent operation.
AVT: The vent valve of a deaeration unit must be kept open.
Condensate water ‘H’ shaped operation
desalination unit
An operation test without using hydrazine was conducted by stopping the unit (WSS), but no significant
differences in cleanup time and water quality were observed. However, hydrazine is a reducing substance and its
use renders the hematite protective layer unstable, which means it may be better to avoid this substance.
In addition, the unit was subject to a startup and stop test while CWT was used in DSS, and no deterioration in
water quality was detected.
The author is determined to continue studies and tests to establish optimum system operation when it is subject
to stop and startup.
3.3.1.6.4 Assessment
Based on the results of these studies and findings in and out of Japan, an assessment was made.
As a result of the assessment, it was found that CWT can be applied to actual units, and is more reliable and
economical than AVT. The assessment details are explained below.
(1) Optimized CWT Operation Method
The author believes Fig. 3.3.1-15 shows the optimized CWT operation method. In this case, no hydrazine will
be used in startup and stop, and neither will any switchover from AVT to CWT take place.
(2) Technical Assessment Comparing to AVT
a. Corrosion of Components
231
Similarly to AVT, the author believes CWT will not have any particularly adverse impacts on the corrosion and
erosion of components.
Moreover, the author also believes that, due to the problems associated with parts using stellite, no basic issues
arise that could deny the CWT applicability. Permanent measures against foreseeable problems are shown in Table
3.3.1-16, while measures for the seat of a BFP overheat prevention valve have already been established. For other
parts, examinations are ongoing.
b. Powers to BFP, etc.
The author believes that the time course increase of steam used for driving BFP found in the acceptance
performance test of the unit using CWT (total amount of heat of low pressure and high pressure steam) can be
substantially decreased to approx. a third compared to AVT, because of the reduced differential pressure of boiler
and of scales deposited.
The author also believes that the functional loss of a high pressure feed heater can be reduced to approx. two
fifths compared to AVT, because of the reduced deposition of scale.
c. Frequency of Chemical Cleaning of Boilers
As shown below, as regards the frequency of chemical cleaning of boilers using CWT, the author believes, in
the case of the No. 1 unit of the Chita No. 2 Thermal Power Plant, that this can be extended from the current 1.5
years to 9.5 years, while for other once-through boilers of supercritical pressure or above, the current 1.5 to 4.5
year period can be significantly extended to 10 to 15 years.
In line with the extension in chemical cleaning frequency, the author believes that regular inspection periods
can be shortened and the disadvantageous transfer of loads eliminated.
(i) Assessment in terms of Boiler Differential Pressure
The interval of chemical cleaning for the unit used in this study, which uses AVT, was 1.5 years due to an
increase in the boiler differential pressure. After switching over to CWT, this increase was eliminated, which
meant the interval of chemical cleaning was extended.
Fig. 3.3.1-27 shows the trend of boiler differential pressure experienced by the Ulsan Thermal Power Plant of
Korea Electric Power Corporation after switching to CWT. The operation time till the pressure rose to the
acceptable limit was 9.5 years, whereupon chemical cleaning took place.
It is considered that the trend of the boiler differential pressure surge of the unit used in this study tends to
follow a path of gradual increase compared to that experienced in Ulsan Thermal Power Plant. However, with
certain allowances taken into consideration, it is estimated that it will take 9.5 years for the unit used by this study
to reach the allowable limit for differential pressure. The author, therefore, believes that the interval of chemical
cleaning for the unit can be extended from 1.5 to 9.5 years.
(ii) Assessment based on the Volume of Scales Deposited on Generation Pipes
The acceptance criteria for the chemical cleaning of boilers employed by this company is around 30 to
45mg/cm2 of scale deposited on generation piles unless other problems, such as abnormal boiler differential
pressure, are observed.
As indicated in 3.3.1.6-(3) ‘Main Components of Boilers,’ the speed of the scales generated will be
0.5mg/cm2・1,000h.
Thus, the chemical cleaning intervals calculated from the scale generation speed are 10 to 15 years, based on
the conditions of the unit utilization ratio of 70% (30 to 40mg/cm2 ÷ 0.5mg/cm2 x 1,000h × 365 days ×24 hours
×0.7).
Based on the above arguments, in the case of other once-through boilers of supercritical pressure or above, for
which no boiler differential pressure need be considered, the author believes that the interval can be extended
from the current 1.5 to 4.5 years to 10 to 15 years.
d. Vibration of BFPs
In the case of the unit used in this study, BFPs were not subject to any vibration, even when using AVT, and
anti-vibration measures remained unconfirmed during the switchover to CWT. However, in the absence of any
waveform scales and the fact that the volume of scales was reduced to approx. one fifth compared to AVT, the
author believes that CWT can represent the ultimate measure against the vibration of BFPs.
e. Environmental Aspects
The use of CWT can eliminate chemicals used to treat feed water and regenerate condensate water desalination
units as well as effluents generated from the chemical cleaning of boilers, thus reducing effluent contamination
loads.
Based on these aspects, CWT can be considered an environment-friendly feed water treatment method.
232
(Legend)
The unit used in this
study
No. 4 unit of the Ulsan
Chemical cleaning
Time
Fig. 3.3.1-27: Differential Pressure of Boilers for the Unit used in this Study
and the No. 4 unit of the Ulsan Thermal Power Plant
233
Table 3.3.1-17: Annual Cost of the No. 1 Unit of the Chita No. 2 Thermal Power Plant
Item AVT Economization Remarks
CWT Ratio
Cost of Power Loss for BFPs 100 Incremental increase of steam used for driving the
33 67 BFPs (actual)
Cost of Functional Loss for High Pressure 100 Deterioration of heat transfer performance (actual)
Feed Heater 40 60
Cost of Installing a Boiler Chemical 100 AVT: Once in 1.5 years
cleaning System 16 84 CWT: Once in 9.5 years (estimated)
Cost of Loss Transferred in relation to the 100 Transfer days: 4 days/time (actual)
above 16 84
Cost of Chemicals for the Treatment of 100 AVT: Ammonia and hydrazine
Feed Water 17 83 CWT: Ammonia and oxygen
Cost of Operating a Condensate water 100 AVT: 56 times (actual)
Desalination Unit 32 68 CWT: 21 times (actual)
Total 100
28 72
Table 3.3.2-1 Raw Water Quality Monitoring Items and Measurement Frequencies
Analyzing Item Frequency Remarks
Daily Weekly Monthly
Turbidity {
pH {
Conductivity {
Ca2+ {
Mg2+ {
Fe2+ {
Alkali ions (Na+ and K+) { By
calculation
Cl- {
SO42- {
HCO3- {
CO32- {
NO3- {
Free carbon dioxide (CO2) {
SiO2 {
Total iron {
Residual chlorine (Cl2) {
COD {
Colloidal silica {
Water temperature {
234
shows a list of water quality monitoring items generally applied for maintaining and controlling the system, and
their measurement frequencies. The frequency must be increased whenever significant fluctuation is observed in
the quality of raw water, or a new water source is employed.
tank using a No. 5 filter. If the filtrated water is normal, then the problem
lies on the filtration unit, as explained in the next chapter.
Incomplete regeneration of a filtration unit x Check whether impurities remain in the filtration unit when the normal
course of regeneration process is done. If necessary, extend the
backwashing time.
x Check whether there is any shortage in the backwashing air and water
flow.
Incomplete water collection unit under the x Check the air dispersion conditions when air backwashing is run. If
filtration unit necessary, open the lower manhole to check it.
Defects to the backwashing trough of the x Check whether effluents from the backwashing process are evenly
filtration unit collected.
Wear or decreased filtration materials x Consider the replenishment of filtration materials.
Channeling of filtration layers x Check whether any impurities and organic slime are found in the
Mad balls filtration layers.
x Repeat the water and air backwashing processes several times.
x Remove the mad balls and replace part of the filtration materials.
Floc strength x Check whether the differential pressure is appropriate for operation by
examining the differential pressure surge from the start of sampling
water and the quality of the processed water.
Insufficient opening of the valves x Insufficient working air pressure
x Damage to valves
Decrease in
amount of
obtaining
Slime inside the filter layers x Operate air backwashing using a filtration material cleaner.
water
or accumulation of foreign matter x Remove foreign matter having accumulated in the upper part of the filtration
Miniaturization of the filtration materials material, if it hinders the discharge of effluents from backwashing.
x Replace the filtration materials on the surface of the filter layers
A slurry circulation type coagulation sedimentation unit requires the maintenance of slurry concentration at an
optimum level, while a sludge blanket type needs the sludge blanket to be kept stable. For both types, the key is
how to adjust the volume of chemicals used as well as that of the sludge discharged from the units. Even without
any dramatic fluctuation in the turbidity and alkali level of raw water, the water temperature varies seasonally,
with a lower water temperature leading to a deterioration in floc formation performance. Experience states that the
threshold temperature is at 10°C or so. If the temperature descends from this level, an auxiliary agent should be
increased to facilitate the floc formation. In the case of a coagulation filtration unit, high water temperature
excessively increases the size of the floc formed and when this happens, the volume of the auxiliary agent should
be decreased. When a separation membrane is used for the desalination unit, the water quality, including the
turbidity and FI (Fouling Index) at the outlet of a pre-treatment unit, must be maintained within the criteria
determined for them. Table 3.3.2-2 shows some examples of turbidity assessment indexes.
In many cases, the problems of a pre-treatment unit are mainly caused by insufficient regeneration of filter
layers due to contamination, which can sometimes be the result of mad balls and mechanical failure of the unit.
When problems involving the filtration unit surface, these can be identified by a deterioration in the quality of
processed water and reduction in the cyclic sampling volume. Table 3.3.2-3 shows the major problems anticipated
to occur with the pre-treatment unit and their measures.
3.3.2.1.3 Control of Deionized Water Generation Unit for Maintaining its Performance
As makeup water for a high pressure boiler requires highly pure demineralized water, the quality of the makeup
water must be controlled. Water treatment items for this purpose include electrical conductivity and silica, and an
indicator and recorder with an alarm are installed at the anion tower of a deionized water generation unit and at
the exit of a polisher to continuously monitor these items. Table 3.3.2-4 shows some examples of water quality
criteria for makeup water used at thermal power plants. The actual values measured by each company, as indicated
in the table, are 1.0µS/cm and 0.01mg/l or below for conductivity and silica respectively.
The following items are examples of daily control items, which should be monitored daily at a fixed time if the
values are measurable:
{ Operation cycles and collection volume per cycle
{ Volume of regeneration agents used and stored
{ Temperature when chemicals are injected to regenerate the anion exchange resin
{ Inner pressure of each ion-exchange resin tower (before and after regeneration)
{ Conductivity of water sampled at the inlet of a deionized water generation unit
{ Conductivity of processed water
{ Silica concentration in processed water
236
Ion-exchange resin should be controlled once a year to measure the total volume of resin replaced and volume
of neutral salt decomposed. At the same time, check the volume of ion-exchange resin remaining in each tower
and inspect whether the resin is finely-divided or not. As for the replenishment of ion-exchange resin, the volume
of resin to be replenished for cation resin is 5% -10% per year, including those finely divided, provided that no
swelling and/or contamination is observed. In the case of anion resin, the volume to be replenished comes to 10%
to 20% per year in general, because it is subject to aging besides the pulverization.
The troubles a deionized water generation unit may encounter mainly include decreased collection volume and
deterioration of the quality of processed water (incl. high conductivity and silica concentration). These problems
are often associated with pre-treatment unit troubles. Table 3.2.2-5 shows the cause of the troubles and their
measures as well as check items.
Table 3.2.2-4: Examples of Criteria set by Each Electric Power Company for
Water Quality at the Outlet of a Circulation Boiler Makeup Water Desalination Unit
Company Name A B C
Pressure Category
130 170 100 130 170
(kgf/cm2) 100 Class 130 Class 170 Class 100 Class
Class Class Class Class Class
Item
Conductivity (µS/cm) 5 or below 1.25 or below 5 or below 3 or 5 or 1.0 or below
below below
Silica (mg/l as SiO2) 0.05 or 0.015 or 0.01 or 0.1 or 0.05 or 0.02 or 0.1 or 0.015 or below
below below below below below below below
Table 3.2.2-5: Troubles (reduced collection volume and decreased purity of processed water)
of a Deionized Water Generation Unit, Their Causes and Measures
Root Cause Cause or Phenomenon of Trouble Measure
Change in Raw Water { Increased total ion volume in raw water { Conduct a total analysis of the raw water and file the data every
Quality { Change in the percentage of Na, HCO3 and SiO2 month (Conductivity must be measured and recorded every
{ Increased organic substances and total iron volume month).
{ Check the water sources.
{ Adjust the ratio of water intake from various water sources.
Oversampling { Inappropriate water flow rate { Compare the data with that of an instantaneous flow meter.
x Failure of a flow meter { Operate by uplifting the water flow.
x Slippage of a flow meter due to the small volume { Refer to the instruction manual attached to the instrumentation
of water passing through unit.
{ Deteriorated water quality { Compare the data with that of a portable water quality meter,
x Failure of a meter etc.
x Failure of a communicator { Connect a resistance box attached to the unit to a cable in lieu
x Sampling failure of a communicator. If the values coincide with each other, then
the communicator is damaged.
{ Refer to the instruction manual attached to the instrumentation
unit.
{ Sampling valve is too far closed or totally closed.
{ Sampling valve is too open.
{ Damages or water leakage to the communicator case.
Incomplete { Insufficient regeneration level { Regenerate the volume specified in the instruction manual. (Or
regeneration increase the level of regeneration)
{ Inappropriate concentration of chemicals { Feed chemicals at an appropriate concentration.
(Insufficient volume or excessive dilute solution { Repair the damaged pipe.
used) { Failure of a chemical feed pump
{ Insufficient dispersion of regeneration agent { Clogs of ejectors and nozzles
x Clogged or damaged chemical feed pipe { Excessive decrease of the diluted water flow rate
x Decreased chemical feed speed (dispersed { Backwash for more than 30 minutes.
unevenly) { Check and remove clogs from the lower water collection and
x Channeling of resin layers dispersion unit.
237
Root Cause Cause or Phenomenon of Trouble Measure
Incomplete { Insufficient extrusion { Measure the specific gravity of regeneration effluents
regeneration (to confirm whether the extrusion force is sufficient or not)
{Insufficient flushing { Analyze the washing effluents
(to confirm whether the concentrations of Cl― of the H tower
and Na+ of the OH tower are the same as those in their inlet
position)
{ Shortage in chemical injection time { Make the total time for chemical injection and for extrusion at
least the same as those designated
{ Inappropriate temperature for chemical injection { Make the temperature of chemical injection as 35±5°C
(if the temperature is lower than this, silica will leak out and if
it is higher, then the resin performance will be deteriorated)
{ Fluidization of resin layers when chemicals are { Readjustment of chemical injection volume and slip water
injected upward volume
{ In the case of a multiple-layer system, a mixture of { Replacement of the mixture of resins in the middle position
mild/strong acid resins and basic resins
Flow-out of { Increased backwashing speed { Check the backwashing speed
ion-exchange resin { Flow out of resins due to excessive backwashing { Check the water temperature
speed
{ Breakage of the lower water collection and { Repair the damaged parts
dispersion unit
{ Flow out of resins to the outlet of an ion-exchange { Conduct a functional test of resins (coarseness distribution,
resin tower etc.)
x Fractured resins due to oxidizing substances
x Fractured resins due to pressurization
Contamination of { Existence of iron oxides and manganese in raw { Check the pre-treatment unit.
ion-exchange resin water
(This contaminates mainly cation resins.)
{ Existence of organic substances in raw water
Channeling { Compressed resin layers
x The raw water is highly turbid. { Backwash thoroughly, or conduct air backwashing to
completely remove turbidity from the resin layers.
x Pulverization of resins due to chemical fracture { Remove residual chlorine in the raw water.
x Pulverization of resins due to a high flow rate { Operate at an appropriate flow rate.
operation or the internal pressure surge of a tank
during operation
x Insufficient or failed backwashing { Backwash thoroughly. (Backwash for approx. 30 minutes, and
stop it just before the outflow of resins from the tank.)
{ Failure of lower and upper distributors { In the case of a heavily uneven surface on the resin surface,
check and improve the upper water distributor so that water can
be distributed evenly.
{ Inspect and repair it.
Low flow rate { The sampling water flow rate is 5m/h or below. { Operate the unit at a high flow rate as much as possible.
sampling This normally results in the leakage of ions from { Don t operate the unit below the minimum flow rate.
(when only the purity an anion resin tower deteriorating.
of processed water is
decreased)
Leakage from a valve { Valve failure { Inspect and repair or replace it.
(when only the purity
of processed water is
decreased)
Deterioration of the { Even in the case that there are no hazardous { Replenish resins as designated.
ion-exchange resin substances in the raw water, the resin function { Measure the degree of functional deterioration and replenish
function generally tends to slowly deteriorate. the resins.
{ Excessive temperature of chemicals { Keep the chemical temperature at an appropriate level.
(Never raise the temperature above 45°C.)
238
the air cooling zones of a condensing unit and nickel plated copper alloy cooling water pipes are laid around the
exterior of the unit.
Iron Concentration
Iron Solubility
Solubility
Iron Concentration
in Feed Water
Temperature
Saturation solubility
of Cu(OH)2 in
deionized water
Saturation solubility
of CuO in deionized
water
Solubility
(Iron)
(Copper)
Concentration
(Nickel)
Fig. 3.3.2-3: Shift in Metal Ion Concentration due to a Change in the Feed Water pH
239
water is close to zero under normal operation, thanks to the upgraded performance of a deionized water generation
unit. However, in the case of seawater leakage, dissolved salts slip into the system. Depending on which materials
are used for the feed heater pipes, namely copper alloy or steel, the means used to control pH to prevent corrosion
of the materials vary. In the case of copper alloy, the pH control mainly targets copper and the value is limited to 9
or so, because dissolved copper ions accelerate the corrosion of iron. The slight volume of ammonia generated by
thermal decomposition of the hydrazine used as a deoxidizer is used to control the pH. Fig. 3.3.2-2 shows a
behavior model of iron in condensate water and feed water systems. The higher the temperature rise, the more iron
ions are generated. Around a high pressure feed heater, the iron ion concentration goes beyond the iron solubility
curve meaning ion deposits are generated. The iron is then deposited in the high temperature zones of high
pressure feed heaters, economizers, boilers and other units. In order to prevent such scales from being deposited, it
is important to minimize the iron ion volume. Fig. 3.3.2-3 shows a change in the iron ion concentration in a course
of a shift in the pH of feed water. As indicated, the pH should be kept high. Fig. 3.3.2-4 shows the solubility of
magnetite (Fe3O4), a corrosion coating. In the high temperature zone, the curve bottoms out at a pH level of
around 10. As iron ions tend to accelerate its oxidization under the existence of dissolved oxygen, hydrazine is
added to the feed water to remove oxygen, so that the generation of dissolved oxygen can be minimized.
N2H4+ → O2+2H2O
A unit using steel pipes is subject to a control pH at around 9.5. Ammonia is directly added to the outlet of a
condenser or deaeration unit as a pH adjuster, and hydrazine is added at the outlet of a deaeration unit as a
deoxidizer respectively.
(3) Boiler Water
Most substances dissolved in boiler water are separated out as the temperature rises, due to the low solubility
and known as scale and sludge. This scale and sludge has low thermal conductivity, causing thermal efficiency to
deteriorate and corroding the boiler generation pipes. With this in mind, the generation of scales and sludge must
be avoided as far as possible. As shown in Fig. 3.3.2-3, the pH of the boiler water must be retained high to prevent
corrosions of generation pipes. Silica contained in boiler water flows out to the steam side and is separated out on
the turbine blades as scales, causing the efficiency of the unit to deteriorate. Therefore, silica concentration must
be minimized as far as possible.
[Once-through Type]
15 - 20 20 or above
Max. Operating Pressure (MPa or kgf/cm2)
Category
Dissolved Oxygen (mgO/l) 0.007 or below 0.02 – 0.2 0.007 or below 0.02 – 0.2
Iron (mgFe/l) 0.02 or below 0.1 or below 0.01 or below 0.01 or below
Copper (mgCu/l) 0.003 or below 0.05 or below 0.002 or below 0.002 or below
Hydrazine (mgN2H4/l) 0.01 or above - 0.01 or above -
Silica (mgSiO2/l) 0.02 or below 0.02 or below 0.02 or below 0.02 or below
240
Iron Ion Concentration (mol/kg)
Fig. 3.3.2-7 shows the JIS criteria. For a drum type boiler, sodium phosphate is used in the boiler intermittently
to control the pH of boiler water. Substances dissolved in the boiler water, such as silica and chlorine ions, are
removed by blowing the boiler water, while in the case of a once-through boiler, all substances dissolved in the
boiler water are separated and deposited as scales, since it lacks any air-water separation mechanisms. This means
the pH of a once-through boiler is controlled by using ammonia, a volatile chemical, and by installing a
desalination unit at the outlet of a condensate water generation system to remove dissolved substances from the
condensate water.
Table 3.3.2-9: Facility Outline of Unit Nos. 1 to 4 Units of the Nishi Nagoya Thermal Power Plant
Unit No. 1 Unit No. 2 Unit No. 3 Unit No. 4 Unit
Output 220 000 kW 220 000 kW 375 000 kW 375 000 kW
Operation started in: July 1970 December 1970 July 1972 September 1972
Boiler type Reheating natural Reheating natural Reheating natural Reheating natural
circulation type circulation type circulation type circulation type
Turbine steam pressure 169 kg/cm2G 169 kg/cm2G 169 kg/cm2G 169 kg/cm2G
(4) Steam
Impurities contained in steam are those carried over from the boiler water, which cause corrosion of superheater
systems and the deposition of scales onto turbine blades. Such impurities include chlorine ions, sodium, silica and
copper. Fig. 3.3.2-8 shows their JIS criteria.
241
As success in steam quality control is significantly dependent on the boiler water quality, for a drum type boiler,
the conductivity of boiler water and its silica content, and - for a once-through boiler - those of feed water at the
inlet of an economizer should be carefully monitored.
To high pressure
turbine
To medium- and
low-pressure turbines
Drum
Flush
tank Deaeration unit water
tank Conden
sate
water
pump
Flush valve Ground
steam
condenser
Flush pipe
drain tank
Makeup
water
tank
Makeup water
pump
243
b. Startup Water treatment
Just after the startup of units, water quality tends to be subject to considerable fluctuation and is under threats
such as seawater leakage and other water quality problems and measurement instrument failures. If these
problems are left unattended, a serious accident will occur. For this reason, water quality targets, blowing
procedures and chemical injection procedures are established for each stop time period. A standard startup
command (operation) sheet shown in Fig. 3.3.2-6 is used to confirm the water quality for each stage to control the
startup water quality, while the standard patterns for dissolved oxygen, silica concentration and conductivity of
water are as shown in Fig. 3.3.2-6. As for the conductivity in particular, a standard pattern for each stop time
period is formed, which is accessible when a recorder is located in the central control room. This pattern is subject
to a comparison check with the current values by a power plant staff member so that the trend can be monitored
and controlled.
c. Off-the-System Blowing
This type of blowing is always implemented till the water quality at the inlet of an economizer and saturated
steam descend below the criteria and till the conductivity shows a falling trend of 0.5 to 0.6µS/cm. (See Fig.
3.3.2-11)
d. Control of Silica Concentration in Steam
It is known that silica deposits are hardly formed on turbine blades when its concentration is below 0.02mg/l.
The silica concentration in steam can be controlled indirectly by managing the level in boiler water. After opening
the system for regular inspections, dust, which is allegedly the source of dissolution of silica slips into the system,
is often carried to a boiler via feed water pipes, where it is then deposited as ionic silica under an environment of
high temperature and pressure. Thus, especially just before system startup after regular inspection, it is vital to
implement the replacement of water and continuous blowing of boilers as practically as possible to reduce silica
concentration in the system, so that silica can be purged completely and swiftly.
244
Preparation for Preparation Ignition Temperature up Pressure vacuum up Preparation for the startup of turbines Turning on of a Parallel in Switchover within Load dispatching
startup for ignition disconnect the plant operation
up
Switchover of burners Startup of turbines switch
Check item
Operation item
Preparation for ignition Ignition and Preparation for the startup of turbines Parallel in Load dispatching operation
temperature/pressure up
Startup of condenser Water quality check Water quality check Water quality check Water quality check
Water quality check
Start up of the feed pump Up of vacuum Startup of turbines Up loads (100MW) Up loads (220MW)
Operation check
Start injection of hydrazine
[Dissolved Oxygen]
(Condensate water)
The concentration of dissolved oxygen falls alongside the
vacuum up in the condenser.
(Feed Water) Condensate water
The dissolved oxygen concentration declines alongside the
surge of pressure of the deaeration unit.
Feed water
[Silica]
When turbines are started, silica scale deposited on the low
pressure blades comes off. (Part of the silica scale comes
from the dead space of the pre-boiler system.)
245
The silica concentration comes down as the blow
operation starts.
Boiler water
[pH]
(Feed Water)
Due to the injection of hydrazine at system ignition, the pH Feed water
level rises.
(Boiler Water)
Due to the injection of hydrazine at system ignition, the pH
level of the feed water rises, as well as that of the boiler
Boiler water
water.
Fig. 3.3.2-6: Standard Startup Command (Operation) Sheet and Startup Water Quality
Fig. 3.3.2-11 Methods of Blow Except the Boiler Water System at Startup
Boiler water blow is implemented until water quality of the eco inlet, the boiler, and the
saturated steam is at the standard value or less, and the conductivity at the CP outlet
shows a declining trend (0.5 to 0.6µS/cm).
Conductivity Silica
Eco inlet or less
Boiler water or less
Saturated steam or less
→Boiler water blow stop
(ANN of silica and conductivity
Conductivity
0.5 or less high have to be reset.)
CP outlet
Shall be on a down note.
The silica concentration in boiler water sometimes exceeds the standard value (0.2mg/l) when the boiler is
sealed (steam sealing) after the unit shut down. The cause seems to be the fact that when the boiler is stopped and
sealed, silica scale separates from the turbine blades, etc., is channeled to the boiler and concentrated when it is
started. To reverse such situation, the following measure is implemented while the boilers are sealed in order to
avoid boiler blow loss and gaining load up during the early stages. When the level of water in a condenser goes up
while the boilers are sealed, the silica concentration in condensate water is measured. If the value is 0.02 mg/l or
more, water is added to the condensate water after total blowing, whereupon the system is started. Following the
implementation of the measure, no abnormal silica concentration up was reported.
(3) Water treatment at Seawater Leakage
It is essential to detect any seawater leakage at an early stage to implement measures. The means of controlling
water quality depends on the seriousness and conditions of the leakage, with appropriate water control measures
sought. For this purpose, conductivity is measured within the condenser, at the outlet of the condensate pump, the
inlet of an economizer and in the boiler water. When the value is found to be high, seawater leakage is present.
Two lines of cation resin towers are installed at the front stage of the condenser and the conductivity meter at the
outlet of the condensate pump, so that the letup time for replacing the resin can be minimized, in the case of
emergencies such as seawater leakage. How to inject chemicals and how to blow boiler water are determined as
controlling water quality in the event of seawater leakage. Also, in a leakage, a process which requires prompt and
correct action is decided. For this purpose, a seawater leakage accident control sheet (Fig. 3.3.2-7) is used to cover
such items as ‘operation method,’ ‘actions done’ and ‘restoration.’
(4) Water treatment Values and Monitoring
Water quality during the normal operation time is monitored and checked for each specimen, using
pre-determined control items and the measurement frequency. All measurement values can be monitored by the
CRT and recorders of the central control room, where staff members are stationed to monitor during the normal
system operation. In the case of an accident, an alarm is activated. Accidents are handled referring to the measures
defined in ‘Water Quality ANN Messaging Procedure’ (Fig. 3.3.2-12).
As water quality requires monitoring of long-term trends, a daily control sheet is formed. Appropriate and
stable operations of the unit are assured and good water treatment methods are established by collecting total
measurement data of iron and copper concentration and in-house inspection results obtained from a regular
inspection and other measures to ensure that water is appropriately treated.
246
3. Causal 4. Restoration
1. Occurrence of an 2. Operation just after
investigation measures
accident the accident
Conductivity high’ ANN turns on. Accident handling Causal investigation Restoration
measures
Point of leakage
(1) Caustic silver check
(2) Switchover of thermometer
(1) Conductivity surges in the order takeout points Repair completed
(1) Boiler water blowing
of condensate water, feed water (2) Injection of sodium tertiary
and boiler water. phosphate
(2) Check the conductivity of the (1) Condenser restored to
confluence points of desalinated normal
water. (2) Boiler steam flushing (See
Note 2)
Seawater temperature at the inlet of Seawater temperature at the inlet of the (3) Restriction of load lifted
condensing water generation unit at 20°C condensing water generation unit at 20°C
or below (See Note 1) or below (See Note 1)
Vacuum of condenser at 690mmHg or Vacuum of condenser at 690mmHg or
above above
If these can be maintained: If these can be maintained:
Load: 220MW Load: 200MW of below
Note 1: In order to avoid any stress corrosion cracks of SH and RH pipes, boilers should be subject to vapor washing when the unit is restored from seawater
leakage (at the turbine rotation of 3,600 rpm).
Note 2: Considering the working environment while only one condenser is in operation, the vacuum is set as 690 mmHg or above (according to a test result in
1980).
Reference information: The conductivity of condensate water was once seen to surge due to pinhole damage of the exterior housing of a condenser water pump.
247
Table 3.3.2-12: Check Sheet for Unit Nos. 1 to 4 Water Quality When ANN is Transmitted
1. Silica and Dissolved Oxygen 3. Abnormal pH Level
* Whether silica and dissolved oxygen concentration tend to be high Check Item Description Cause
or not is checked by referring to the checksheet. Feed water pH High (or low) b d
Check Item Description Cause Boiler water pH High bdh
Silica Low abd
concentration is Makeup water There is considerable conductivity of
c d
high. makeup water.
Makeup water 1.5µS/cm or above for the makeup c Chemicals
water Chemical Chemical concentration and type
10µg/l or above at the outlet of the concentration
makeup water desalination unit b
Failure of pumps Switchover test of injection pumps
Load Load surged Addition of
(when silica is purged) i chemicals Stroke and valve operations
Measurement The ANN of a measurement d
instrument instrument is transmitted. Cause and Measures
The dissolved Cause Measures
oxygen a. Seawater leakage a. x See the section of seawater
concentration is leakage.
high. x See Accident Action Procedure.
Load Load decreased e b. Excessive (too small) b. Adjust the injection volume.
Deaeration unit Check the inner pressure of the f hydrazine injection
system. c. Abnormal quality of c. x In the case of abnormal quality of
Switchover of Check whether any O2 is leaked or g makeup water makeup water, blow the water in
the condensate not by switching the condensate Leakage of regeneration the makeup water tank.
pump pump agent of a desalination unit
Drain pump Check whether any O2 is leaked or g and sampling after breakage
not at the drain pump seal. d. Fault of measurement d. If adjusting the flow rates and
Measurement The indication does not change d instruments temperature does not work,
instrument after switching the specimen inform Chemical G.
water. e. Decreased loads
f. Deteriorated deaeration
2. High conductivity/Condenser・High conductivity/Seawater unit
leakage at startup g. O2 leakage from g. Seal the leakage.
Check Item Description Cause condensate pump and drain
pump
Check the The conductivity of the
h. Excessive addition of h. Adjust the volume.
relationship of the condensate water and water in the
sodium tertiary phosphate
following: system suddenly surges from the
a i. Surge of loads i. x Blow the boiler water.
Condensate water, normal level, followed by feed
x See the section explaining the
feed water, boiler water, boiler water, saturated
relationship of silica in boiler
water, saturated water. The makeup water is intact.
water and pressure.
steam and The conductivity of the makeup
makeup water in water surges, followed by others c
the system such as condensate water.
Chloride ions Adding caustic silver changes the
a
water turbid in white.
Measurement Their conductivity fluctuates
d
instrument separately.
Table 3.3.2-13: Facility Outline of Unit Nos. 1 to 4 Units of the Sodegaura Thermal Power Plant
Unit No. 1 Unit No. 2 Unit No. 3 Unit No. 4 Unit
Output (MW) 600 1 000 1 000 1 000
Operation started in: August 1974 September 1975 February 1977 August 1979
Boiler type Reheated
once-through Same as left Same as left Same as left
type
Boiler capacity (t/h) 1 900 3 110 Same as left 3 170
Steam pressure (kg/cm2) 246/42.1 246/40.1 Same as left Same as left
Steam temperature (°C) 538/566 Same as left Same as left Same as left
Fuel used LNG Same as left Same as left Same as left
d. Replenishment of Resins
Referring to the results of the performance check, resins are replenished to maintain the function of a
condensate water desalination unit at the appropriate level. The volume of resins replenished annually is 10% for
248
cation exchange resin and around 20% for anion exchange resin.
Table 3.3.2-14: List of Water Quality of Supercritical Pressure Through the Flow Boiler at Normal Times
Specimens taken Analysis item Criteria
Makeup water Conductivity < 0.5 µS/cm
Silica concentration < 30 µg/l
Outlet of a condensate Conductivity < 0.5 µS/cm
pump
(CP out)
Outlet of a condensate Conductivity < 0.15 µS/cm
water desalination unit Sodium concentration < 5 µg/l
(CBP out) Total iron concentration < 5 µg/l
Total copper concentration < 2 µg/l
Outlet of a Dissolved oxygen < 7 µg/l
desalination unit concentration
(Dea out)
Inlet of an economizer pH 9.3 to 9.6
(Eco in) Conductivity < 0.25 µS/cm
Total iron concentration < 5 µg/l
Total copper concentration < 2 µg/l
Hydrazine concentration < 10 µg/l
Silica concentration < 20 µg/l
Table 3.3.1-16: List of Storage Methods when the Plant is Subject to Shutdown
Stop time Boiler Deaeration unit Condenser Feed water heater
Steam side Feed water side
Within 56 hours Hot banking In circulation mode Retains the ordinary Storage in vacuum Retain the shutdown
water level. condition or in steam status.
sealing
Within 72 hours Storage after filling Normal water level + Retains the ordinary N2 pressurization Storage by filling
water +N2 pressurization Steam sealing water level. water
[or N2 pressurization]
(Hydrazine: 20 to 30 (Hydrazine: 20 to (Hydrazine: 20 to
mg/l) 30 mg/l) 30 mg/l)
More than 72 Dry storage after sealing Dry storage after Dry storage Dry storage after Storage by sealing N2
hours N2 sealing N2 sealing N2 or dry or by filling water
(RH: Dry storage) storage (Hydrazine: >300
mg/l)
(2) Water treatment at Startup and while the Unit is not used
a. Water treatment while the Unit is not used
The most important thing in water treatment while the unit is not used is to minimize the inclusion of exterior
air inside the system to prevent corrosion. The following three measures are conducted for this purpose:
(1) Hot banking that puts a boiler under a pressurization condition to eliminate the inclusion of exterior air
(2) After a boiler has cooled down, a high concentration of hydrazine is infused to minimize the area
contacting with air, while also helping remove the dissolved oxygen from the contact area.
(3) After a boiler comes to a stop, boiler water is purged and blown out by pressurized nitrogen while keeping
the boiler temperature at 100℃ or above to keep it in a dry condition.
249
Fig. 3.3.2-16 shows how to store the plant when it is not in use. The table categorized the storage method by the
period of storage. In the case that the planned short time storage is subject to change in the longer storage period,
the storage method for the plant must be changed. Sampling racks are stored by closing the valves and after filling
with deionized water.
b. Water treatment at Startup
Before starting the plant, it is subject to a cleanup process by dividing the system into 3 blocks of condenser,
feed water system and boilers respectively. The controlled items for this purpose include, for a cold cleanup
process, iron and mill scales, etc., with those that are generated during the time the plant is not in use analyzed. To
check the iron concentration, two methods are used; the membrane filtration and automatic measurement methods.
The former compares the color of the filter after filtration of sample water with the standard color, while for the
latter, an iron meter of the particle counting method or the scattered light method is used. The control criteria of
the iron concentration is set as 300 µg/l or below as a target, while Fig. 3.3.2-17 shows other water control criteria.
In addition, the injection of ammonia and hydrazine, etc. is possible to combat corrosion of the system and
maintain the quality of water in the systems at the appropriate level. In injecting chemicals, Mode PB on the
sampling rack is selected. Fig. 3.3.2-18 shows a worksheet of a chemical feed unit.
In the Sodegaura Thermal Power Plant, a patterned operation is used for the blowing time and chemical
injection in order to control iron concentration, etc. at the appropriate level. The pattern was formed based on the
experience of the plant. More recently, more plants have been able to automatically control and operate water
treatment and chemical injection using a computer. In the Sodegaura Thermal Power Plant, the iron concentration
of feed water at the inlet of an economizer after ignition of the plant is controlled to 50µg/l or below as a target.
The criteria for collecting drain water generated by each process is, 300µg/l or below for iron collected by a
condenser, and 50µg/l or below for that collected by a feed water system.
250
Table 3.3.2-17: List of Water Quality of a Supercritical Pressure Through a Flow Boiler at its Startup
Startup process Sampling at: Analyzing item Criteria
Surge of condenser vacuum - - Condenser Vacuum
> 680 mmHg
Water feed to a condenser desalination CP out Total iron concentration < 300 µg/l
unit Hydrazine concentration < 10 µg/l
Pre-boiler system blow stop CP out Total iron concentration < 300 µg/l
Hydrazine concentration < 10 µg/l
Water feed to boilers Dea out pH 9.2 to 9.6
Total iron concentration < 100 µg/l
Dissolved oxygen concentration < 50 µg/l
Boiler system blow stop WW out or SH Total iron concentration < 300 µg/l
out Hydrazine concentration < 10 µg/l
Ignition Eco in pH 9.2 to 9.6
Conductivity < 1.0 µs/cm
Total iron concentration < 50 µg/l
Total copper concentration < 10 µg/l
Dissolved oxygen concentration < 10 µg/l
Silica concentration < 30 µg/l
WW out pH 9.2 to 9.6
Conductivity < 1.0 µg/l
Humidified circulation Eco in pH 9.2 to 9.6
Conductivity < 1.0 µs/cm
Total iron concentration < 50 µg/l
Total copper concentration < 10 µg/l
Dissolved oxygen concentration < 10 µg/l
Silica concentration < 30 µg/l
WW out Conductivity < 1.0 µs/l
Aeration to turbines - 1/2 loads Eco in pH 9.2 to 9.6
Total iron concentration < 50 µg/l
Total copper concentration < 10 µg/l
Silica concentration < 30 µg/l
Collection by condenser - Total iron concentration < 300 µg/l
Collection by condensate - Total iron concentration
Drain water
< 50 µg/l
collection
251
Table 3.3.2-18: Chemical Injection Workflow Sheet
Plant process Circulation of
condensate water
Circulation of the Circulation of the Circulation of
deaeration unit pre-boiler the boiler Normal operation
Stop
Fe: 300 ppm or
Water treatment values below Hot banking Normal storage and
N2H4: 10 ppm or DO: 50 ppb plant not in use:
below or below 10 ppb or above N2H4: 10 ppm or
above
Sampling rack mode
Circulation Circulation Circulation Circulation Aeration of
Lamping High Low Normal Delamping Parallel off
of of the of the of the the main Storage method
end pressure pressure
PB process condensate deaeration pre-boiler boiler steam pipe heater heater
operation
water unit Hot Ordinary
Stop
banking storage
Kick signal
Injection of a high
concentration of hydrazine
Program control with the for 4 hours
conductivity at the outlet of
Stroke length a demister as a preceding Constant value control of conductivity at the inlet of a deaeration unit with the Program control with the
control signal
conductivity at the outlet of a demister as a preceding signal
conductivity at the outlet of a Injection of a
demister as a preceding signal
constant volume
Ammonia pump
RPM control
In proportion to the condensate water flow rate
As above
Program control with the
conductivity at the outlet of
Stroke length a demister as a preceding Constant value control of conductivity at the inlet of a deaeration unit with the Program control with the
conductivity at the outlet of
control signal conductivity at the outlet of a demister as a preceding signal a demister as a preceding
Injection of a
signal constant volume
RPM control
In proportion to the condensate water flow rate
As above
Hydrazine pump
Ammonia
Open
Open
Hydrazine
Open
252
To the outlet of
From HPx1HTR
HPHTR
From HP2HTR
To the
boiler
blow
tank
Drain tank
LP-HTR
Drain P
Steam A
and B
To the boiler
blow tank
253
From the
outlet of
CBP
Fig. 3.3.2-20: Designated Water Volume of the Condensate water Desalination Unit
and Water treatment criteria
Designated collection NH4 Type 384 000 (m3)
volume H Type 35 000 (m3)
Water treatment (outlet Conductivity 0.15 (µS/cm)
water quality) Sodium ion concentration 5.0 (µg/l)
e. Drain Collection
Drain is blown to the outside of the system at the same time with the startup of the feed water heater. Drain of
the low-pressure feed water heater is collected to the condenser when the iron concentration becomes 500 µg/l or
less. Moreover, when the iron concentration becomes 50 µg/l or less, it is collected to the condensate water pipe.
Similarly, drain of the high-pressure feed water heater is collected to the condenser when the iron concentration
becomes 50 µg/l or less. When the iron concentration becomes 50 µg/l or less, it is collected to the deaerator.
254
Fig. 3.3.2-21: Stoppage Patterns (Category) and How to Store each Component
Stoppage Stop time Within 72 hours 72 hours to 1 week 1 week or longer
Category Boiler stop Normal stop Forced cooling Normal stop Forced cooling Normal stop Forced cooling
Component condition
Condenser Retained Destructed Retained Destructed Retained Destructed Retained Destructed
vacuum
Boiler body Hot bank Same as left Pressurized sealing Same as left Hot bank Storage after Hot bank After decreasing
When the pressure is of N2 After decreasing the filling 100mg/l After decreasing the the pressure, the
decreased pressure, the boiler is of hydrazine pressure, the boiler is boiler is filled
Pressurized sealing of filled with 100mg/l of filled with 200mg/l of with 200mg/l of
N2 hydrazine for storage. hydrazine for storage. hydrazine for
storage.
Pre-boiler Valve is closed like Same as left Same as left Same as left Same as left Storage after Same as left After decreasing
during normal Like the case of a filling 100mg/l Like the case of a boiler, the pressure, the
operation. boiler, the pre-boiler is of hydrazine the pre-boiler is filled boiler is filled
filled with 100mg/l of with 200mg/l of with 200mg/l of
hydrazine for storage. hydrazine for storage. hydrazine for
storage.
Deaeration unit Hot bank Same as left Pressurized sealing Same as left Hot bank Storage after Hot bank After decreasing
When the pressure is of N2 Like the case of a filling 100mg/l Like the case of a boiler, the pressure, the
decreased boiler, the pre-boiler is of hydrazine the pre-boiler is filled boiler is filled
Pressurized sealing of filled with 100mg/l of with 200mg/l of with 200mg/l of
steam or N2 hydrazine for storage. hydrazine for storage. hydrazine for
storage.
Low pressure feed water heater Valve is closed like Same as left Same as left Same as left Same as left Storage after Same as left After decreasing
during normal Like the case of a filling 100mg/l Like the case of a boiler, the pressure, the
operation. boiler, the pre-boiler is of hydrazine the pre-boiler is filled boiler is filled
filled with 100mg/l of with 200mg/l of with 200mg/l of
hydrazine for storage. hydrazine for storage. hydrazine for
storage.
From condenser to the inlet of the low Cleanup Same as left Same as left Same as left Same as left Storage after Same as left After decreasing
pressure feed water heater Circulation continued Like the case of a filling 100mg/l Like the case of a boiler, the pressure, the
boiler, the pre-boiler is of hydrazine the pre-boiler is filled boiler is filled
filled with 100mg/l of with 200mg/l of with 200mg/l of
hydrazine for storage. hydrazine for storage. hydrazine for
storage.
Shell side of feed water heater Retained under Pressurized Retained under Pressurized Same as left Same as left Same as left Same as left
vacuum condition. sealing of N2 vacuum condition. sealing of N2
Superheater and reheater Valve is closed like Same as left Same as left Same as left Same as left Same as left Same as left Same as left
during normal
operation.
255
Table 3.3.2-22: Scope of Cleanup and Water Quality Criteria
Cleanup process Water quality Water quality criteria for approving the cleanup process Scope of Remarks
measurement pH Cationic Dissolved Hydrazine Total iron cleanup
point conductivity oxygen concentration concentration
(µS/cm) concentration (mg/l) (mg/l)
(mg/l)
Condensate Blowing Outlet of a 9.8 1.50 or 0.500 From a
water condensate below condenser
pump to the inlet
Circulation Outlet of a 9.4 0.15 or 0.200 0.050 of a low
condensate to below (Outlet of a pressure
condensate water
pump 9.7 booster pump)
feed water
heater
Deaeration Blowing Outlet of a 9.5 0.50 or 0.500 From a low
unit deaeration to below pressure
circulation 9.7 feed water
pump heater to a
Circulation Outlet of a 9.5 0.50 or 0.10 or 0.200 0.050 deaeration
deaeration to below below unit
circulation 9.7
pump
Pre-boiler Blowing Pre-boiler 9.5 0.50 or 0.500 From the
cleanup pipe to below outlet of a
9.7 deaeration
unit to a
Circulation Pre-boiler 9.5 0.50 or 0.10 or 0.200 0.050 high
cleanup pipe to below below pressure
0.7 feed water
heater
Boiler Blowing Outlet of a 9.5 0.50 or 0.500 From the
water separator to below outlet of a
9.7 high
Circulation Outlet of a 9.5 0.50 or 0.10 or 0.200 0.050 pressure
water separator to below below feed water
9.7 heater to a
boiler
Condensate water
pump
Return valve
Sampling Sampling
valve valve
Conductivity
meter
Resin tower
Resin tower
Sampling
Sampling
Flow meter
257
For this reason, when seawater leakage is detected, its remaining capacity is checked immediately. During normal
operation, an ammonia type sampling is switched to H type sampling, on a par with the volume of leakage, and
the standby tower starts operation. With these measures, loads are reduced as soon as possible to contain the
volume of seawater slipping into the system. Table 3.3.2-14 shows the actions taken for a 1,000MW class boiler.
Table 3.3.2-23: Example of Actions when Seawater Leakage Happens to a Condenser (Example)
Surge of Conductivity
at the Outlet of CP Actions Taken
(µS/cm)
Rated Water Quality Treatment Cl-Concentration
1/2 load Actions for Operation Others of Condensate
load Blowing Chemical Injection water
1. To strengthen 1. Continuous blowing 1. Chemical injection 1. To close the
monitoring by a. To be done to boilers condensate water
monitoring immediately after a. To inject 10l of return valve
instruments detecting seawater sodium tertiary connected to a
2. Determination of the leakage phosphate to the distilled water
location and degree of b. Intermittent blowing drum when tank
leakage depending on the continuous 2. To conduct a
Lower than Lower
3. Examination for leakage conditions blowing starts water-pressurized -
6 than3
starting operation and (manual inspection, b. To inject an leak check
inspection plans etc.) appropriate
2. Blowing of condensate volume of sodium
water tertiary phosphate
a. To be done so that the pH
depending on the level of boiler
leakage conditions water can be
1. One condenser 1. Continuous blowing maintained at 1. To check and
operation To be done around 9.5 repair the
(To stop damaged continuously 2. Chemical injection damaged
condenser and to 2. Rapid blowing to feed water condenser while
operate the intact To be done in the case a. To switch operating the
3 or condenser that water quality check hydrazine intact one 0.3 ppm or
6 or above
above continuously at the revealed it necessary injection from (Inspection using above
1/2 load) (Openness: 10% to automatic mode a vinyl sheet)
2. To confirm that the 15%) to manual mode
conductivity at the 3. Blowing of condensate (Target: pH of
outlet of CP, etc., has water feed water to be
decreased To be done around 8.8)
1. Reduction or stop of continuously * As seawater
the spray flow rate for (Fully open in elements causes
10 or 5 or an uplift of 0.5 ppm or
a superheater and principle, but subject to
above above conductivity, it is above
reheater adjustment depending
2. To reduce load on conditions) not possible to
1. To stop the unit in 1. Total boiler blowing as control the pH 1. To check and
principle necessary level by adjusting repair the
20 10 it. 1.0 ppm
damaged
condenser
258
which water heated up in a heat exchanging process is evaporated in a cooling tower to be cooled by discharging
evaporative latent heat for use in recycling, and a closed circulation type, in which heated water is cooled down in
a cooling water cooler using seawater. A large capacity power generation plant in Japan uses the closed circulation
type, which can then be categorized into systems where bearing cooling water tanks are installed and those using
stand pipes. Recently, the latter has been frequently used because of the ease of water treatment.
These component cooling water systems incorporate an oil cooler that cools down the lubricants used for
turbine rotors, etc., a hydrogen cooler that is used for cooling generator and a coolant cooler. These units are made
of aluminum brass. Controlling the water quality of such component coolants should involve consideration of the
selection of an appropriate coolant circulation method and the use of steel, copper and copper alloys. Based on
such views, the water treatment of component coolants involves the introduction of anti-corrosion agents into the
coolants, in order to prevent the corrosion of the heat exchanger cooling pipes as well as other pipes, in turn, to
prevent scale deposits on the heat exchanger and avoid deterioration of its heat exchanging function.
Table 3.3.2-24: Example of Water Quality Treatments to a High Hardness Cooling Water System
Volume of circulation water: 20,000 m3/h
Operation Condition of Cooling Water volume retained: 13,000 m3
Tower Temperature difference in a cooling tower: 8°C
Concentration : 2.5 times
Initial injection:
Anti-corrosion agent: Kurizetto S370 (polymer phosphate series) 400mg/l
Anti-scaling agent: Kurizetto T225 (polymer series) 200mg/l
Chemicals Used Normal operation:
Alkali treatment agent: Kurizetto S113 (phosphate - polymer series) 40mg/l
Chlorine treatment: 0.5 to 1.0mg/l(Cl2) 3 h/day
Slime control agent: Polyclin A496 (nitrogen compounds - polymer series) 50mg/l x month
Partial Filtration of Circulation Sand filtration: 3% (against circulation water volume)
Water
Makeup water Circulation water
Turbidity (degree) 2 5
pH (at 25°C) 8.1 9.0
Conductivity (µS/cm) 350 1 000
Water Quality Calcium hardness (CaCO3 mg/l) 170 380
M alkali level (CaCO3 mg/l) 180 400
Chloride ion (Cl-mg/l) 20 63
Sulfate ion (SO42-mg/l) 31 79
Silica (SiO2 mg/l) 7 18
Treatment Periods 7 years
Results of Effects using a Test
Corrosion rate (SPCC) [mdd] 3 to 4
Piece
A small volume of scales and sludge was observed in several low speed heat exchangers, but other heat
Result of a Regular Inspection
exchangers were in good condition without any corrosion scales, slime and sludge damage.
259
Unlike highly hard water, water with low calcium hardness tends to require an increased concentration of
anti-corrosion chemicals and it is necessary to raise the concentration of anti-corrosion agent to 10 to 15
mg/l(T-PO4) under the calcium hardness of around 100 mg/l(CaCO3) and 15 to 20 mg/l(T-PO4) in the case of 50
mg/l (CaCO2). This is because the phosphate series anti-corrosion agent is influenced by dianoinic metals, such as
calcium ions, and because the combined use of phosphate and zinc salts with a strong coating forming
performance can achieve good anti-corrosion performance, even if the concentration of anti-corrosion chemicals
is kept to a low level. In a low hardness cooling water system, scales such as calcium phosphate can be formed in
a high temperature zone, and anti-scaling agents, such as acrylic acid series polymers and maleic acid series
polymers, are generally used in combination with these chemicals. In an open circulation type cooling system,
operation under a high concentration of chemicals to save the volume of water can thicken nutrients contained in
the water and within such an environment, microbes can pullulate and slime be formed relatively easily. In order
to prevent this, measures are taken by sterilizing the microbes and adding anti-slime agents that are effective in
curtailing the reproduction of the same. For such purposes, the hypochlorites and cyanurates previously used have
been recently replaced by carbonyl series compounds with no corrosion effects. Tables 3.3.2-24 and 3.3.2-25 show
examples of water quality treatment at open circulation type cooling systems.
Table 3.3.2-26 shows the water quality analysis items and frequency of analysis that are usually used for the
operating control of an open circulation type cooling system, while Table 3.3.2-27 shows the significance of these
water quality analysis items.
Table 3.3.2-25: Example of Water Quality Treatments to a Low Hardness Cooling Water System
Volume of circulation water: 5 000 m3/h
Operation Condition of Cooling Water volume retained: 2 400 m3
Tower Temperature difference in a cooling tower: 12°C
Concentration : 3 times
Initial injection:
Anti-corrosion agent: Kurizetto S370 (polymer phosphate series) 400mg/l
Kurizetto S611 (zinc salt series) 100mg/l
Chemicals Used Normal operation:
Anti-corrosion agent: Kurizetto S603 (phosphonates, phosphates and zinc salts) 50mg/l
Anti-scaling agent: Kurizetto T225 (polymer series) 30 mg/l
Chlorine treatment: Polyclin A411 0.3 to 1.0mg/l(Cl2) 3 h/day
Partial Filtration of Circulation Sand filtration: 3% (against circulation water volume)
Water
Makeup water Circulation water
Turbidity (degree) 2 7
pH (at 25°C) 7.2 7.9
Conductivity (µS/cm) 100 254
Water Quality Calcium hardness (CaCO3 mg/l) 24 72
M alkali level (CaCO3 mg/l) 23 47
Chloride ion (Cl-mg/l) 5 18
Sulfate ion (SO42-mg/l) 6 15
Silica (SiO2 mg/l) 6 15
Treatment Periods 8 years
Results of Effects using a Test
Corrosion rate (SPCC) [mdd] 3 to 5
Piece
Result of a Regular Inspection Corrosion, scale and slime were hardly observed and the result was very good.
Table 3.3.2-26: Water treatment Items and Analyzing Frequency for Operation Control of an Open Circulation
Type Cooling System (Standard)
Analysis Item Frequency of Analysis
Makeup Water Circulation Water
Turbidity (degree) Once a week Once a week
pH (at 25°C) Once a week Once a day
Conductivity (µS/cm) Once a week Once a day
M alkali level (CaCO3 mg/l) Once a week Once a week
Calcium hardness (CaCO3 mg/l) Once a week Once a week
Chloride ion (Cl-mg/l) Once a week Once a week
Sulfate ion (SO42-mg/l) Once a week -
Silica (SiO2 mg/l) Once a week -
Total iron (Fe mg/l) Once a week -
Residual chlorine (Cl2 mg/l) - -
CODMin (O mg/l) Once a month Once a month
Anti-corrosion agents (mg/l) - Once a day
There are several ways to monitor the effectiveness of an anti-corrosion agent, the representative methods of
which include (1) measuring the corrosion speed of a test piece, (2) measuring the corrosion speed using a
corrosion measurement device using a polarization resistance method (an electrochemical method), (3) confirming
the conditions of corrosion and erosion depth on the heat transfer surface of a pipe using a heat exchanger for
260
monitoring purposes. The use of a test piece or a corrosion measurement device to measure the corrosion speed
cannot confirm the corrosion conditions on the heat transfer surface, in which case a heat exchanger for
monitoring purposes can be used. However, this method is not generally used, because the conditions of pipes
cannot be confirmed during test periods (normally 1 to 3 months) and because it requires significant plant and
operation control costs.
Table 3.3.2-27: Significance of Each Water Quality Analysis Item
Item Significance
pH Measured to obtain the trend of corrosion behavior and scale formation of water. The pH level of circulation water
(at 25°C) is normally controlled at 7.0 to 9.0. Where the level is decreased to 6.5 or below, it must be raised by the addition
of alkali agents. In this case, the appropriate pH level is 8.0 to 9.0.
Conductivity Measured to determine the trend of salt concentration dissociated into water as ions. Generally speaking, water
(µS/cm) quality with high conductivity tends to be bad and is frequently a cause of corrosion damage.
Turbidity Measured to determine the volume of suspended matter in water. Since the presence of such suspended matter in
(degree) the system can cause deterioration of efficiency and erosion damage to a heat exchanger, the turbidity of the
circulation water should be retained as low as possible.
M alkali level There is a certain degree of connection between pH and the degree of alkali. The M alkali degree is an indicator of
(CaCO3 mg/l) the trend of calcium carbonate forming scales.
Calcium hardness This indicator is important to control the concentration of circulation water and to determine the trend for the
(CaCO3 mg/l) formation of scales by calcium and other compounds such as calcium carbonate.
Chloride ion This is generally used as an indicator for controlling the concentration of circulation water. For a system where
(Cl-mg/l) chlorine treatment is performed, this indicator is used in combination with others, such as conductivity, calcium
hardness and silica concentration, etc. Water containing high chloride ions tends to have strong corrosive
performances.
Sulfate ion Water containing a high concentration of sulfate ions tends to have a strongly corrosive performance. As for HAVC
(SO42-mg/l) coolants, the inclusion of sulfur acid gas contained in the air into the system causes a high concentration of sulfate
ions and decreases the pH level, forming a highly corrosive environment.
Silica Silica is one of the causes of scale formation.
(SiO2 mg/l)
Ammonium ion Water containing a high concentration of ammonium ions is highly inclined to generate slime. For a system using
(NH4+/l) copper series materials, ammonium ions and copper react with each other to form a complex ammonium ion salt,
which is a cause of corrosion.
Consumption of oxygen A system with a high consumption of oxygen tends to cause slime, meaning appropriate slime control measures
[CODMin ] must be implemented.
(O mg/l)
General microbe count It can be an indicator to know the generation of slime. It can also be used to judge the effectiveness of the
(pcs/ml) microbicide.
Total iron The total iron content in the circulation water includes iron ion and colloidal ion derived from the makeup water as
(Fe mg/l) well as other iron generated by corrosion of the system. The existence of iron can cause secondary corrosion,
meaning the total iron concentration must be kept as low as possible.
Concentration of It is necessary to constantly maintain the concentrations of anti-corrosion and anti-scaling agents at an appropriate
anti-corrosion agents and level. In the case of significant fluctuations, effective anti-corrosion and anti-scaling performances cannot be
anti-scaling agents expected.
(mg/l)
Table 3.3.2-28: Outline of Anti-Corrosion Agents for a Closed Circulation Type Cooling System
Anti-Corrosion
Applicable Water System Corrosion Rate Remarks
Agent
Polymer Phosphate Retention period: Within 10 Carbon steel: 5 to 20 mdd As this agent facilitates the discharge of corrosion products
Series days Copper and copper alloys: outside the system, a corrosion speed of 5 to 20 mdd may
Makeup water: Industrial water 1 mdd or be acceptable.
Fresh water below Use polymer agents in combination with it to reduce the
generation of scales on heat transmission surfaces.
Nitrate Salt Series Retention period: 10 days or Carbon steel: 1 mdd As this agent does not allow the easy discharge of corrosion
more Copper and copper alloys: products outside of the system, a chemical that ensure
Makeup water: Industrial water 1 mdd or favorable anti-corrosion performance must be used.
Softened water below As the maximum temperature of bearing coolants is 40°C
Deionized water or below, which is within the optimum growing
temperature for microbes oxidizing nitrate salts (generally
15 to 30°C), it is necessary to use its inhibitor in
combination with it.
Molybdate Retention period: 50 days or Carbon steel: 10 mdd When this agent is used in a system in which no or
Polymer Series more Copper and copper alloys: insufficient anti-corrosion treatment is performed, iron
Makeup water: Industrial water 1 mdd or oxides existing in the system can be washed away turning
Softened water below the color of the coolant red. In such systems, it is necessary
Deionized water to flush it before starting injection of this chemical.
3.3.3 Future Prospects
With unit size subject to rapid growth since the introduction of large-sized components after WWII, a daily
water treatment method has almost been established following the era of trials and errors. However, many
problems still remain to be solved depending on the location of a thermal power plant, in order to further advance
the method of water treatment.
The first involves how to raise the reliability of supplying sufficient energy. Considering recent advancements
of society and economic growth, it cannot be said that sufficient energies are guaranteed. Under current conditions,
where it is increasingly difficult to build a new power plant, currently available systems should be used as long as
possible. The issues to be solved in order to ensure the patterns of water treatments, established based on the
experiences of thermal power plants to advance into stricter and more assured means of water treatment, include
raising the accuracy of the devices used to monitor water quality as well as measures against seawater corrosion of
condenser pipes, in terms of materials.
The second issues to be solved include (1) a reduction of carbon dioxide emissions that is considered to be a
cause of global warming, (2) shortening the system operation time to maintain and uplift the heat efficiency of
boilers from the viewpoint of energy saving and the appropriate use of energies, (3) the introduction of such
methods as oxygen treatment to prevent scale attachment to boilers and (4) reduction in the ammonia volume used
for the removal of nitrogen and phosphorus from effluents.
The third issues include plant maintenance. Water treatment is a decisive factor in preventing the corrosion of
components. With this in mind, it is important to occasionally conduct a water quality inspection to assess the
quality of water in the system and to determine the volume of oxygen and metal ion concentration, in order to
conduct appropriate anti-corrosion measures.
262
3.4 Turbines and Auxiliary Machines
3.4.1. Maintenance of Steam Turbines
Maintenance of steam turbines includes minor repairs (for example, retightening of a gland packing for a
valve) during a patrol and major repairs during periodic maintenance, among which replacement or improvement
of a faulty part may be included. There are two kinds of maintenance, one is daily repair to be effected whilst
the turbine remains in operation or the electric generation is stopped and another is periodic maintenance where
the electric generation is periodically stopped for a long time.
263
3.4.1.4 Special Maintenance
Accumulated operating hours of many of the then new and advanced thermal power plants in Japan that were
the motive power for the rapid development of the Japanese economy are reaching one hundred thousand hours or
more. It is time for them to be thoroughly inspected in a systematic manner.
Desirable items to be inspected are listed below.
(2) Blades
a. Embedded portion.............. Inspection to check whether the roots of the first and second stage rotors of the high
and the medium pressure turbines that are exposed to high temperature have lifted
Ultrasonic test of the rotating blades in each of the high, and the medium pressure
stages
b. Shroud tenon...................... General inspection to check whether it lifted and how it lifted
(3) Main steam check valve... Liquid penetrant test of the inside and outside surface, magnetic particle test,
ultrasonic test, hardness test and structural examination by means of a microscope
(4) Turbine casing.................. Penetrant test of the inside and outside surface, magnetic particle test, structural
examination by means of a microscope
264
V⋅T: Visual Inspection U⋅T: Ultrasonic Test
Table 3.4.1-2: Major Items of the Periodic Inspection Legend P⋅T: Penetrant test R⋅T: Radiographic test
Operation : Inspection M⋅T: Magnetic particle test
Number of Inspection
No. Place to be Inspected Inspection Method Remarks Illustration and Reference Point
Tested Samples Frequency
1 Usual inspection
(1) Casing
The inside
a. Corners and the inside V⋅T, M⋅T 100% inspection Every two years In our experience, cracks are liable to occur of a pipe
surface of each pipe due to concentration of heat stress in the seat
b. Nozzle chamber
(a) The inner and the V⋅T, M⋅T, A mirror 100% inspection Every four years (1) Removing the nozzle plate, carefully check
outer surfaces for inspecting the the base part of the nozzle vane, the corners of
inside of a pipe the nozzle chamber, the welded part, etc.
(2) Carefully check the shape of the internal A welded
connecting part
threads of the nozzle plate fixing bolts.
M⋅T, U⋅T
(b) The welded M⋅T, U⋅T 100% inspection Every four years It is a matter of concern that self-excited
connecting part vibration of the nozzle chamber occurs with
increased clearance between the casing and the
nozzle chamber causing too much stress in the
welded base part resulting in a crack there.
(c) Profile Dimensions 100% inspection Every four years It is necessary to monitor the total deformed
(Deformed amount) amount of the nozzle chamber since it is one of The inside of the nozzle
chamber
the parts of a steam turbine that is subject to
V⋅T, M⋅T, A mirror to
the severest conditions and creep deformation Deformed amount of the profile inspect the inside of a pipe
may occur after a long time operation. Measurement of the dimensions
a, b and c
(d) Fitted part Dimensions 100% inspection Every four years It is necessary to monitor the clearance
(Clearance) between the casing and the nozzle chamber
every year since it may increase due to
repeated knocks caused by vibration generated
by vapor flow.
(e) Vane Dimensions 100% inspection Every four years Increased eroded amount causes unfavorable
(Eroded amount) influences such as decreased turbine efficiency,
weakened strength of the rotating blades, etc.
Measuring point
It is necessary to carefully monitor a turbine
unit with which starts and stops are frequently
repeated especially because it may suffer from
outstanding increase in the eroded amount.
Eroded amount
265
Operation : Inspection
Number of Inspection
No. Place to be Inspected Inspection Method Remarks Illustration and Reference Point
Tested Samples Frequency
c. The spot-faced part of V⋅T, M⋅T 100% inspection Every two years The corners and the spot- faced part are liable
the horizontal joint to cracking. Inlet Sleeve Spot faced portion
d. The inlet sleeves V⋅T, M⋅T, 100% inspection Every two years Carefully observe tearing-off, scoring and
Dimensions cracks on the border of an area to which stelite
is coated. The maintenance of dimensions of
bearing seal ring and seal ring is also
important.
e. Hole Plug for the M⋅T, Dimensions, 100% inspection Every two years The Hole Plug should be carefully inspected so
balance hole Shape of the screw that it may be easily removed and installed as
threads needed. Inspection of the male and the
female threads should be assuredly effected
since its coming off during operation may
result in a serious accident. Hole Plug Stopper
Outer Casing
f. Balance tube M⋅T, U⋅T 100% inspection Every two years Cracks in the welded part and the extent of
(Wall thickness) reduction in the wall thickness of the inner part
of the vent should be controlled. Hole Plug Hole Plug head
clearance
g. Welded part 100% inspection Every two years Cracks are liable to occur in the welded part of Inner Casing
V⋅T, M⋅T
the pipe base and also to the trace of the
welding for repair effected when it was
manufactured among the wide welded area.
Inspect the male and the female
It is also desirable to concentrate the inspection threads of the Hole Plug
on the welded part of the Low Pressure Casing
Stay.
h. Key V⋅T, Dimension 100% inspection Every four years It is necessary to control the clearance to be
(Clearance) appropriate at all the keys accessible for
Inner
inspection so that expansion and shrinking of
Casing
the casing may not be constrained.
b. Main Steam Inlet Piping The outer surface: 100% inspection Every four years Remove Pipe Base and the welded part of
Drain Pipe Base V⋅T, M⋅T Drain Pipe and observe the inside of Main Pipe The welded outer
The inner surface: A and the welded part of Pipe Base by means of a surface of the seat for
mirror to inspect the inside of a pipe. the Extraction Tube
mirror to inspect the
inside of a pipe Effect M⋅T on the outer surface.
Main Steam Inlet Piping
Drain Pipe Base
266
Operation : Inspection
Number of Inspection
No. Place to be Inspected Inspection Method Remarks Illustration and Reference Point
Tested Samples Frequency
(3) Rotor Rs
a. The R portion of the V⋅T, M⋅T 100% inspection Every four years The small size parts near the inlets of the high
outer surface pressure and the medium pressure steam and
the bottom of the dummy groove require
inspection.
b. Shoulders of the V⋅T, U⋅T 100% inspection Every two years In case the T root is used to embed the first The shoulder part of the first stage
The outside blades of the medium pressure turbine
grooves in the rotor of stage blade of the medium pressure, check
diameter of the rotor
the medium pressure whether any cracking occurs in the inside by
turbine where the the outer surface(U.T) of the wall of the groove
blades are embedded for the blade. Hollows in the rotor in which
the entry blades are embedded
c. The outside diameter Dimensions The area around Every four years Whether creep deformation has occurred can
of Rotor the steam inlet be determined by change in the rotor outside
A crack
(High and medium diameter. In this method, measuring points
pressure turbine rotors) should be fixed to grasp the yearly change in
the outside diameter.
d. Hollows where the side V⋅T, M⋅T, U⋅T 100% inspection Every four years Apply the same method as that used for the
entry turbine blades are root of the rotating blades.
embedded
e. Pump Shaft V⋅T, M⋅T 100% inspection Every four years It is desirable to remove the vane of the main
oil pump and to measure the part with the least
cross section and some other parts. (An area in which the blades are embedded)
Erosion
Lifted amount Tenon
Shroud Tenon
(4) Rotating Blades Shroud
Rotating
a. Tenon, Shroud Ring (1) V⋅T, M⋅T, 100% inspection Every four years Lifting of the shroud may be caused by heat direction
Measurement of due to sheering or touching of the tenon This
the lifted problem is common in rotating blades.
amount of the
shroud ring
(2) Measurement of 100% inspection Every two years In the event of serious erosion, part of the
Shroud ring cracks
the eroded caulked tenon is lost. This problem should be
amount of the observed. A unit that is subject to frequent
tenon starts and stops should be observed carefully. Cracks
b. Welded parts of the V⋅T, P⋅T 100% inspection Every four years In some cases, fine cracks occur in an area of
stubs the rotating blade of the low pressure turbine to
which the metal is welded. Especially for an
old blade where TIG welding was yet to be Cracks in the welded part of the stub
used, special observation is required.
c. Portions that make the Measurement of the 100% inspection Every two years The rotating blades near the main inlet and the Erosion of the part making the profile
profile eroded amount reheat inlet are liable to be eroded. It is
necessary to grasp secular changes in the
profile by means of mold transferring using a
standard gauge and compound as an additional Cross-section
of a blade
means.
267
Operation : Inspection
Number of Inspection
No. Place to be Inspected Inspection Method Remarks Illustration and Reference Point
Tested Samples Frequency
d. The blade root area of V⋅T, M⋅T, U⋅T 100% inspection Every four years Both for the blade and the disk, the highest
the side entry blade stress is experienced at the corner on the first
tooth. The inspection is to be effected by
means of M⋅T and U.T according to necessity.
However, in case the inspection has to be
carried out in a limited space such as the high
or medium pressure stage, P.T will be used. A crack in the blade root
e. An area of the blade in
the low pressure stage The blade
on which stelite is base metal
Erosion
deposited. Silver
(a) Eroded amount 100% inspection Every two years According to the erosion, the condition is to be solder
V⋅T
classified as follows and recoating should be
effected according to a planned schedule.
A crack Separation
(1) The surface is somewhat rough.
An image taken during R.T showing
(2) The surface is pitted.
incomplete fused spray of stelite
(3) The erosion has reached the base metal.
Special care should be paid to the leading
blades of a group since they are liable to be
Erosion
eroded.
(b) Separation and P⋅T 100% inspection Every two years Immediately recoat any cracked blade or where
cracking separation has propagated to a wide area.
(c) Bonding condition R⋅T (or U.T) All the recoated When recoated Make sure without fail that they have been
blades well bonded because the bonded condition Blade Ring
when the coating is effected is very important.
Valve seat
268
Operation : Inspection
Number of Inspection
No. Place to be Inspected Inspection Method Remarks Illustration and Reference Point
Tested Samples Frequency
c. Valve Seat V⋅T, M⋅T (P⋅T) 100% inspection Every time when Cracks are liable to occur in a part coated by
overhauled stelite. A stelite deposited part should be
inspected by means of P.T.
d. Flange surfaces of the Hardness Representing On and after the It is desirable to measure the hardness of the
main body points 5th year Main Steam Stop Valve that is exposed to the
(Only for the Main Every two years severest conditions among the valves and to
Steam Stop Valve) monitor secular changes in order to grasp the
tendency of its softening due to creep.
Dimensions About two Every four years For a unit of which the service time has
representing exceeded 8~10 years, measure the internal
bolts per area and the pitch diameters every four years.
Checking of the - ditto - Every four years For the profile of the threads, copy the
thread profile profile by means of compound and
periodically observe secular change of the Actual profile Standard profile
cross section.
Checking of the profile of the female threads
269
Operation : Inspection
Number of Inspection
No. Place to be Inspected Inspection Method Remarks Illustration and Reference Point
Tested Samples Frequency
2 Secular deterioration check
(1) Rotors
a. The center hole V⋅T, P⋅T, M⋅T, U⋅T All the planes Once at 100,000 For a rotor where a blind hole is drilled in the
Dimension hours in service center, another of which defect was found
(inner diameter) and every ten during the inspection of the center hole
years thereafter effected when it was manufactured and others
of a unit that has been operated with frequent
starts and stops, it is desirable to inspect in a
short cycle of period.
b. Grooves for the blades V⋅T, M⋅T (or by P.T) Rotors of the 1st Once at 100,000 For a rotor having semicircle rotating blade
(For the T root and the to 5th stages in hours or so in fixing metals, it is desirable to sample some Blades
double T root types) the high pressure service rotating blades and inspect them since it is a
turbine matter of concern that cracking will occur in Rotor
Rotors of the 1st the rotor side of the seating surface of the
and 2nd stages in metal and also in the corner of the jaw in the
the medium groove for the blade in the rotor. Caulking Piece
pressure turbine Also for a rotor that is equipped with a flat
fixing metal since it was manufactured, it is A crack
desirable to check its secular deterioration by
A crack
an inspection method such as U.T from the
outside (for the 1st stage of the medium
pressure turbine) because cracking may occur
in the jaw of the groove for the blade in the
rotor.
Lift
Rotor
b. Portion representing Measurement of Several 8th to 10th year It is desirable to control softening of the
the profile hardness representative and every four material used for the rotating blades every four
(Blades near the main (by means of X-ray rotors years thereafter years since the material may possibly be Measurement of
steam and the reheat diffraction or other deteriorated after prolonged service under high hardness of the surfaces
representing the profile
steam inlets) methods) temperature and this can be detected by
measurement of the hardness. X-ray
diffraction is available for the measurement of
hardness as an inspection method without
making any dent in the blade.
270
Operation : Inspection
Number of Inspection
No. Place to be Inspected Inspection Method Remarks Illustration and Reference Point
Tested Samples Frequency
(3) Stationary blades Measurement of 100% inspection 8th to 10th year It is a matter of concern that creep deformation
(Blades near the main inclination amount and every four occurs to the stationary blades in the 1st stage
steam and the reheat of a blade row years thereafter of the high or the medium pressure turbine
steam inlets) after prolonged exposure to steam of high
temperature and high pressure so that
difference in elongation between the rotor and Steam
the casing is constrained.
Amount of inclination
(4) Bolts exposed to high Destructive test One or two Every four years Select the place where the severest operational
temperature and high representative condition is realized and perform tests such as
pressure bolts per material examinations of structural transformation,
creep, low cycle fatigue, mechanical, etc.
271
3.4.2 Maintenance of Condensers
3.4.2.1 Inspection and Measures
Table 3.4.2-1 shows content of the maintenance and inspection to be effected at the periodic inspection.
Table 3.4.2-1: Content of the Maintenance and Inspection to be Effected at the Periodic Inspection
Timing of Inspection
Item Purpose or Method Countermeasure/Improvement
Maintenance Method
1 The inside of the • Inspection as to whether or not When the water VI • Clean it with a brush or something
cooling pipes clogging of the pipe with chamber is opened ET similar.
foreign matter, corrosion or • Install a stop plug in pipes that water
erosion has occurred cannot pass through due to clogging.
• Effect anti-corrosion or anti-erosion
treatment and install a stop plug as a
precaution.
• Replace the clogged pipe with a new one.
2 The outer surface • Inspection of erosion and When the main body VI • Install a stop plug in the damaged pipe.
of the cooling pipe damage is opened • Effect the anti-erosion treatment.
• Replace the damaged pipe with a new
one.
3 The surface of the • Inspection as to whether or not When the water VI • Clean it with a plastic scraper, deck
pipe plate and how marine creatures and chamber is opened brush, etc.
dirty matter adhere
• Checking of the connecting
part of the cooling pipes
4 The inside of the • Inspection as to whether or not When the water VI • Repair the damaged part.
water chamber a swell, separation, damage or chamber is opened PHT • Clean it with a plastic scraper, deck
a pin hole has appeared on the brush, etc.
rubber lining
• Inspection as to whether or not
and how marine creatures and
dirty matter adhere
5 The inside of the • Inspection of erosion and When the main body VI • Replace the eroded part with a new one,
main body shell damage caused by steam and is opened PT and install a protective cover.
drain attack, and inspection of • Clean the hot well.
the burned out part
• Inspection as to whether or not
any scale or dust has been
deposited.
6 The pressure- • Inspection as to whether or not When the main body VI • Repair the damaged part.
resistant portion of any cracking has occurred in the is opened PT
the main body shell shell plate, welded part, or WT
fixing part of the nozzle stub
7 Connecting piece • Inspection of deterioration of Once a year after the VI • Replace them with new ones after about
the rubber the rubber expansion joint by five cumulative ST ten years.
expansion joint viewing from the inside of the years since the first WT
body steam extraction
8 The extraction • Inspection as to whether or not Once a year after the VI • Repair the damaged or broken part.
steam pipe damage, breakage, adhesion. five cumulative PT • Establish a schedule to replace it with a
expansion joint etc. has occurred years since the first new one after 20 years.
steam extraction
9 The feed water • Inspection as to whether or not When the main body VI • Repair the damaged or broken part.
heater outer cover damage, breakage, etc. has is opened PT
(Lagging) occurred
V.I.: Visual Inspection E.T.: Eddy Current Test P.T.: Liquid Penetrant Test
W.T.: Leak Test by Filling Water S.T.: Hardness Test P.H.T.: Pin Hole Test
3.4.2.2 Cleaning of the Water Chamber and the Surface of the Pipe Plate
Negligence in cleaning of the water chamber and the surface of the pipe plate allows marine creatures to
adhere to them and strongly propagate on them so that the cooler pipes are so persistently clogged, requiring too
much labor to remove them. Therefore, cleaning of the water chamber and the pipe plate shall also be scheduled
whenever a planned shutdown or opening of the water chamber is expected.
272
3.4.2.3 Cleaning of the Inside of the Cooling Pipes
Cleaning of the inside of the cooling pipes is important to maintain the performance of the condenser, and
Table 3.4.2-2 shows the method of cleaning. However, it is necessary to check the properties and condition of
the scale deposited on the inside wall and to select an effective method since it may be different according to such
properties and condition. When the pipe is clogged with foreign matter, remove it first, and then carry out the
cleaning.
3 Cleaning with a Scale containing a • Feed by pressurized water a rotary tube cleaner with a water gun.
rotary tube cleaner small amount of algae • Wet the tube cleaner in advance.
• Feed the cleaner in the direction of the flow of the cooling water at first, and
afterwards, feed it against the direction of the flow.
4 Cleaning with a Hard scale • Use a neutral cleanser; never use a chlorine- or acid-containing detergent.
chemical detergent • Do not effect this treatment until it is ensured that the discharged rinsing water
has been completely neutralized to be harmless to the environment.
(1) Wrapping sheet (very thin plastic film) method (4) Water-filling method
Rubber packing
(5) Fluorescent agent method
(2) Water manometer method Rubber packing
Point of leakage Point of leakage
Foam Transparent Rubber plug
acrylic resin
Foam cap
Application of
A vacuum meter soapy water
(3) Foam method Vacuum-breaker
Vacuum pump (6) Vacuum pump method
(an ejector)
Check valve
Compressed air
273
(1) Wrapping sheet (very thin plastic film) method
This method makes it possible for the unit to be operated with a single system. One end of the pipe plate is
blocked by a rubber plug, and the other end is covered by wrapping sheet or both ends are covered by the
wrapping sheet, and leakage is detected by a hollow in the sheet.
Turbine casing
Flon or
helium gas
Rubber expansion joint Low-pressure
feedwater heater
Connecting piping
Connecting piping
Gas detector
Connecting
Connecting piping piping
Air-cooling section
Vacuum pump
274
3.4.2.6 Eddy Current Test (9)
The built-in-type eddy current test is a checking method to find damage to the cooling pipes. This checking
should be effected at every periodic inspection, and the data should be compared and arranged in good order
according to the passage of time. The eddy current test is a detection method that utilizes electromagnetic
induction. There are two methods: synchronized detection and phase analysis. Both or only the latter should be
effected. As shown in Figure 3.4.2-3, passing an alternative current through a coil situated near a metallic
material causes an eddy current in it due to electromagnetic induction. Such defects as cracks or any variation in
the material properties would change the eddy current, changing the impedance of the coil.
The AC coils
The condition of the cooling pipe can be known if this change in impedance is converted to voltage and
recorded using a suitable electric circuit. Figure 3.4.2-4 shows how the flaws are detected.
Synchronized Synchronized
detection method detection method
Synchronized Synchronized
detection method detection method
Since this method can only detect variation in the volume due to damage, a sample pipe should be extracted
corresponding to the wave form, and correlation between the wave form and any damage should be established.
New pipe
Procedure for expanding and
Procedure for pipe replacement then blocking a pipe
Figure 3.4.2-5: Procedure for Replacing and Blocking a Cooling Pipe
275
(2) Measurement of dimensions
Measurement of such dimensions as inclination, elongation, and shrinkage.
(4) A leak test by filling water shall be effected when the rubber expansion joint is replaced with a new one.
Metal part
1. Removal of the copper alloy tubes Water chamber Inlet of the turbine bypass
(1) Current situation (2) Cutting off of the copper alloy (3) Removal of
pipes, Removal of water the copper alloy pipes
chamber and pipe plate
2. Replacing of the existing pipes with titanium ones
(a) Method of replacing only the cooling pipes and the pipe plate
The pipe plate
Titanium pipe plate Protective device for the turbine bypass
The stakes
Welding of the
titanium pipe
Newly fabricated water chamber
(6) Installation of the pipe plates on
(4) Installation of the pipe plate on the side opposite (5) Insertion of the side from which the pipes Expansion of Installation of the stakes
to the side from which the titanium pipes are to the titanium pipes are inserted and installation of the pipes
be inserted, the protective device for the turbine the water chamber, Welding of
bypass, and the newly fabricated water chamber the titanium pipes, P.T. (Liquid
penetrant test), The water-filling
(b) Method of replacing the pipe bundle module test
Figure 3.4.2-7: Procedure for Replacing of the Aluminum Brass Alloy Pipe Condenser by the Titanium Pipe
Condenser
276
Table 3.4.2-3: Examples of Main Failures Occurring in the Feed water Heater
Part Name Item of Failure
[Monel metal] Stress corrosion cracking
[Brass] Ammonium attack
Drain attack
Heating [Steel pipe] Inlet attack
Stress corrosion cracking
[Stainless]
Drain attack
Deposit of scale
Diaphragm of the cylindrical water chamber Fatigue damage
Seal ring of the breech lock-type water chamber Cracking in the welded part
Extraction steam nozzle Cracking in the welded part
Body and the parts inside the body Erosion, thickness reduction, cracking due to thermal stress fatigue
Diaphragm in the water chamber Erosion, thickness reduction, cracking in the welded part
capability of the heating pipe the pipe are becoming rusty Renewing the equipment, Chemical washing, Jet water
Function
277
Table 3.4.2-5: Maintenance Items of the Feed water Heater
Maintenance
No. Operation Mode Maintenance or Monitoring Item
Frequency
Once every hour Level of the drain
1 to once every few In service Opening angle of the valve
hours Water quality control
Level of the drain
2 Once a day In service Opening angle of the valve
Water quality control
Level of the drain
Once a day to
3 In service Opening angle of the valve
once a month
Water quality control
Level of the drain
Once a month to
4 In service Opening angle of the valve
once a year
Water quality control
During a halt in operation Checking of the inside of the water chamber
5 Once a year (during the periodic Replacing and checking of the packing
inspection) Checking of the performance
During a halt in operation Checking of the inside of the body, Measuring of the wall thickness
Once every five to
6 (during the periodic Checking of the heating pipe, Measuring of the wall thickness (E.T.)
ten years
inspection)
Deterioration of the material Cracking due to erosion of the Inspection of the inside
of the nozzle materials around the steam Ultrasonic measurement of the body wall thickness
inlet, the drain inlet, the outlet
of the condensed water, etc. and
thermal stress fatigue
Table 3.4.2-8 shows the main items of maintenance. These items of maintenance and their frequency are just
for reference, and they depend on the kind of the plant. Therefore , it is necessary to obtain information on other
plants and to operate a plant in cooperation with the suppliers in the same manner as explained later on the causes
of and measures against representative examples of failures listed in Table 3.4.2-6.
278
Table 3.4.2-8: Maintenance Items of the Deaerator
Maintenance
No. Operation Mode Maintenance or Monitoring Item
Frequency
Once every hour Level of the drain
1 to once every few In service Opening angle of the valve
hours Water quality control
Level of the drain
2 Once a day In service Opening angle of the valve
Water quality control
Level of the drain
3 Once a month In service Opening angle of the valve
Water quality control
Level of the drain
Once a month to
4 In service Opening angle of the valve
once a year
Water quality control
During a halt in operation Inspection of the inside
5 Once a year (during the periodic Replacement and checking of the packing
inspection) Inspecting the inside of the body
During a halt in operation Checking of the functions
Once every five to
6 (during the periodic Inspecting the inside of the body, Measurement of the wall thickness
ten years
inspection) (Inspection of the tray and spray valve)
279
Table 3.4.2-9: Maintenance Items to be Effected during Scheduled Suspension of Operation and Periodic
Inspection
Name of Equipment Inspection Item Method Frequency Countermeasures
Inspection of the inside Inspect whether or not Once every six months Effect washing with a
of the cooling pipes and how scale adheres to one year brush or something
and foreign matter is similar.
deposited. Review the frequency
- Clean them when of the cleaning.
necessary (V.I.).
Inspection of corrosion Inspect corrosion of Once a year Install a stop plug or
of the cooling pipes both the inside and the replace the pipe with a
outside of the pipes new one.
using ECT.
Inspection of leakage Apply water or air Once every two to three Re-expand the pipe.
from the expanded part pressure to the inside of years Install a stop plug.
and other parts of the the body, and inspect Replace the pipe with a
Seawater cooler cooling pipes whether or not there is new one.
leakage.
Inspection of the Visually inspect Once every two to three Apply epoxy resin
surface of the pipe plate corrosion of the pipe years coating to the eroded
plate surface (V.I.). area of the pipe plate.
Inspection of the inside Inspect whether or not Once every six months Repair/clean the lining
surface of the water the rubber lining is to one year
chamber damaged (V.I. and pin
hole check).
Inspect how the marine
creatures adhere (V.I.).
Inspection of the Inspect the consumed Once a year Replace the anode plate
galvanic anode plate amount of the anode with a new one.
material (V.I.).
Inspection of corrosion Check whether or not Once every two to three Install a stop plug.
of the cooling pipes any part of the outside years
or the inside of the pipe
is corroded.
Condenser cooler Inspection of leakage Apply water (oil) Once every two to three Re-expand the pipe.
Oil cooler from the expanded part pressure or air pressure years Install a stop plug.
of the cooling pipes to the inside of the
body, and inspect
whether or not there is
leakage (V.I.).
V.I.: Visual Inspection ECT:: Eddy current test W.T.: Pressure test (Water, Air, or Oil pressure)
It is necessary to effect an eddy current test (ECT) at every periodic inspection for a cooler using seawater.
However, the frequency of ECT for a condenser cooler and an oil cooler may be somewhat reduced provided that
the water is appropriately treated to reduce the causes of cooling pipe corrosion.
A stop plug must be fitted in a pipe whose wall thickness is found by ECT to be too greatly reduced or when
such a pipe must be replaced with a new one. Figure 3.4.2-8 shows the procedure for fitting a stop plug in a pipe.
280
3.4.3 Preventative Maintenance and Remaining Life Assessment techniques of Equipment and
Components used in a Steam Turbine
Causes Effects
Creep
A creep deformation
A creep rupture
Time Fatigue
Low-cycle fatigue Material deterioration
High-cycle fatigue Increased
Temperature
possibility of
Aged deterioration Embrittlement
damage
(Aged deterioration Stress Corrosion Strength reduction
of quality) Corrosion fatigue
Stress corrosion Increased
Environment operating cost
Start and stop cracking
Performance down
Load fluctuation Erosion
Corrosive Solid particle attack
Drain attack
Softening
Abrasion
The inlet temperature of a steam turbine is as high as 500°C or more, and the steam at the final stage where it
finishes its expansion is in the wet condition at a temperature of about 33°C and at a wetness fraction of about
10%.
Various kinds of deterioration occur due to the difference in the operating conditions mentioned above.
1.1 Creep
A material that is subjected to a load under high temperature gradually deforms and finally cracks and breaks.
This phenomenon where a material gradually deforms is called creep, and the cracking or the breaking is called
creep rupture.
281
A start of a Growth of a
Inter-granular slide microscopic crack microscopic crack
1.2 Fatigue
Figure 3.4.3-3 systematically shows the process of formation and diffusion of a fatigue crack.
A crystal grain The direction of
repeated stress
A crack in the slip
zone appearing at
the initial stage
A cleavage crack
The outside The direction of growth The inside
(The inside) (The outside)
A ductility striation
1.3 Embrittlement
Materials used for steam turbines are exposed to high temperature during operation for a long time, and their
toughness and ductility are reduced. Brittleness is the result of this process and is progressive as time passes.
The turbine wheel casing, the rotor, the main valve, etc. that are used under high temperature are liable to
suffer from this phenomenon.
Generally speaking, brittleness that appears after heating at high temperature for a long time is caused by
segregation of such trace elements as phosphorus (P) and tin (Sn) reducing the grain boundary strength.
Figure 3.4.3-4 systematically shows the process of aged brittleness occurring to the materials used in steam
turbines.
282
Acceleration of the grain
Diffusion of trace Grain boundary segregation boundary segregation
elements of trace elements and embrittlement
Embrittlement occurs at temperatures of 350°C or higher, and does so in a relatively conspicuous manner in
the temperature range between 450° and 500°C.
When a material becomes brittle, its resistance to unstable rupture (brittle fracture) and its ductility are reduced,
and diffusion velocity of a crack is increased at the same time. For this reason, a big cracking may start from a
point where stress concentrates such as a subsisting casting defect. It is necessary to extend the warming-up time
in the rotor in order to prevent bursts that may occur in a cold start.
1.4 Corrosion
The stage of a turbine near the dry-wet alternating area that becomes wet with a heavy load and dry with a
light load is an area where corrosion must be especially observed. In such an area, a phenomenon occurs where
traces of corrosive substances dissolved in water droplets sometimes condense due to the alternation between a
wet condition and a dry condition caused by load fluctuation or by starting and stopping.
And corrosion and pitting occur more or less in a steam turbine that has been operated for a long time because
when the steam turbine stops, steam becomes droplets that attach to the metal surface even near the last stage
where wet steam flows and in the higher stage where the temperature is higher.
1.5 Erosion
Erosion that occurs to materials used in a steam turbine is mainly caused either by solid particles or by drain
(water droplets).
1.6 Softening
The necessary strength and ductility of the materials used for the parts exposed to high temperature are
maintained by heat treatment. However, various mechanical properties related to the strength are deteriorated
due to the effects of temperature and stress caused by operation under high temperature for a long time. One of
these phenomena is softening.
The higher the temperature and the stress, the more conspicuous the softening.
Softening of a material used in a turbine can be detected by measurement of hardness.
1.7 Abrasion
Although the gasket installed between the rotor and stationary parts such as the nozzle is a non-contact type,
light contact between them may occur due to deformation of the wheel casing during a thermal transitional period
such as the start-up of the turbine.
Gaskets are gradually abraded due to light contact resulting in increased leakage of steam between two stages
to cause aged deterioration of efficiency.
Journals of the rotor and bearings can suffer from abrasion and sliding scratches after prolonged operation.
2. Object Components and Areas in a Steam Turbine to be Assessed and Damage to Them
2.1 Object Components and Areas to be Assessed in a Steam Turbine
The rotor, the wheel casing, the rotating and stationary blades, and the main value are the objects of periodic
maintenance and life control because they are the main components of a turbine.
Figure 3.4.3-5 to 9 show the object components and areas of each item of main equipment for which life
assessment must be effected.
The T-root
type
The dummy groove
The medium- The place of the tenon
The medium-pressure The high-pressure pressure rotating
rotating blades A shroud
rotating blades blades
The profile
A rotor
The center hole
The dummy part The outside surface
The side entry type
Figure 3.4.3-6: Object Components and Areas of the High- and Medium-pressure Rotor (impulse type)
for Which Life Assessment Must be Effected
284
The profile
The low-pressure
rotating blades A disk The part consecutively
connected by metal parts
one by one
A corner R portion
A main steam nozzle A corner R portion
A bolt
The flat
portion
Section A - A
Figure 3.4.3-8: Object Components and Areas of the High-pressure Wheel Casing
for Which Life Assessment Must be Effected
A bolt
Figure 3.4.3-9: Object Components and Areas of the Main Valve (Steam-adjusting Valve)
for Which Life Assessment Must be Effected
285
Table 3.4.3-1: Main Parts of a Steam Turbine and Causes of Damage
Cause of Aged Deterioration Test
Remaining life
assessment
Embrittlement
Corrosion
Softening
Abrasion
Erosion
Fatigue
Equipment Place/Component
Creep
UT MT PT VT
Photo 3.4.3-1: Creep damage to the Tenon for a medium-pressure rotating blade
286
(2) Fatigue cracking damage to the base part of the high- and medium-pressure disk
Photo 3.4.3-2 shows an example of low-cycle fatigue cracking damage occurring to the base part of the high-
and medium-pressure rotor due to repeated thermal stress caused by starting and stopping of the turbine.
Thermal stress occurs due to temperature difference between the inside and the surface of the disk. This is
caused by the large heat capacity of the rotor, leading to disagreement in temperature between steam and the
metallic part when the steam is introduced and also to inability of the inside of the disk to follow the rapid
increase in temperature afterwards.
Moreover, since stress concentration occurs around the corner and the groove parts of the rotor surface, plastic
deformation is repeated every time the turbine is started and stopped, leading to accumulated fatigue and finally to
cracking.
(3) Corrosion fatigue damage to the part of a rotor in which rotating blades are embedded
Photo 3.4.3-3 shows an example of the corrosion fatigue occurring to the part of a low-pressure rotor in which
a rotating blade is embedded.
Impurities or corrosive substances in steam concentrated in the gap between the rotor and the rotating blades
cause corrosion pitting. Starting from a pit, a fatigue crack develops and expands because the fatigue strength of
a material is reduced under a corrosive environment.
A crack
The first hook
A specimen to be
taken The second hook
The third hook The starting point
(The outlet side) (the inlet side)
Photo 3.4.3-3: Corrosion Fatigue of the Part of a Rotor Where Blades are Embedded
287
(1) Remaining life assessment by a destructive test (direct assessment method)
Among the test methods using destructive tests, one is where the specimens are sampled from the materials of
an actual turbine in service, and another is where the materials thrown away are utilized.
Table 3.4.3-2: An Example of Techniques for Remaining Life Assessment by a Non-destructive Test
Cause of
Assessment Method Parameters to be detected Instruments/Measuring Method
Damage
Measurement of hardness Hardness A portable hardness tester
Measurement of hardness together Hardness A portable hardness tester
with analytical calculation
Measurement of electric resistance Electric resistance An electric resistance-measuring
device
By A parameters Creep void The replica method
Creep
By the average length of the void Creep void The replica method
By the area rate of the void Creep void The replica method
By the mean area rate of the Carbides The replica method
carbides
By comparison of the structures Voids, Minute cracks, Structural The replica method
(Area affected by welding heat) change, Precipitated substances
Measurement of microscopic Length of microscopic cracks The replica method
cracks
Measurement of hardness Hardness A portable hardness tester
Fatigue
Measurement of hardness together Hardness A portable hardness tester
with analytical calculation
Measurement of X-ray diffraction Half-value width An X-ray diffraction device
Polarization Current density A polarization test device, A small-
size electrolysis cell
Embrittlement
Chemical etching Surface roughness, Intergranular A surface roughness tester, The
corrosion cleavage width replica method
288
(i) A method by means of measurement of hardness(2) ~ (6)
The hardness of the low-alloy steel for equipment used in steam turbines that is exposed to high temperature
drops due to the change in the metal structure under high temperature (deformation resistance change). This
drop in hardness occurs even with no load as shown in Figure 3.4.3-10 (heating with no load) and is accelerated
by a load being imposed.
Heated material with no load
Before heated
Temperature Heated Materials that
(°C) material received creep
with no load damage
450 { ⎯⎯
500 U S
Materials
550 { { that received
550 creep
damage
[Cr-Mo-V steel]
Figure 3.4.3-10: Relation between the Temperature Time Parameter and Hardness
The hardness test method assesses the creep damage rate by means of the amount or rate of hardness drop
measured in actual steam turbines. Figure 3.4.3-11 shows the relationship between creep damage rate φc and
drop in hardness ∆Hv (difference in hardness between a material with a load applied and another with no load
applied), and the creep damage rate is obtained from the measurement of hardness making use of the figure.
Figure 3.4.3-11: Relation between Creep Damage Rate and Drop in Hardness
(ii) A method of using hardness measurement together with analytical calculations (1)
This method assesses the creep damage rate by means of creep rupture characteristics after deterioration that
are obtained from hardness measured in an area that received thermal aging (an area exposed to high temperature
but only to low stress), as well as by means of the analytical calculations. Figure 3.4.3-12 shows the summarized
test results of creep rupture characteristics represented by hardness and temperature time parameters. And creep
rupture characteristics after aged deterioration are obtained from measurement of hardness on actual steam
turbines and the calculation result of temperature and stress by Formula (1) that is induced from the figure.
T(C+logtr)={Σai⋅(logσ)i-1⋅Hv+Σbi⋅(logσ)i-1 ........................................................................... (1)
where tr: Creep rapture time
T: Absolute temperature
C: Material constant
Hv: Vickers hardness
σ: Working stress
ai⋅bi: Approximation constants
289
Stress σ (kg/mm2)
(Estimation according
to the formula (1))
Values obtained by
experiments
Figure 3.4.3-12: Comparison between Data on Creep Rupture Characteristics Obtained from Experiments and its
Estimation Based on Measured Hardness
Figure 3.4.3-13: Relation between Creep Damage Rate and Dropped Amount of Electric Resistivity Ratio
290
Photo 3.4.3-5: An Example of an Observed Creep Void by Means of a Replica
(i) The replica (ii) Transfer of (iii) Picking up (iv) Vapor deposition of gold
film the structure the replica (to give the replica electric conductivity)
A crack or a void
A carbide
The replica
For creep, there is a special feature where at first, formation of a creep void is recognized during the process of
damage and it develops, expands, and combines to become a crack through a microscopic crack. There is a
correlation between the situation of void formation and the creep damage rate.
The following methods are proposed for quantifying the occurrence of a void.
(i) The “A” parameter method
(ii) The mean length of void method
(iii) The area rate of void method
(iv) The mean area of carbide method
(v) The structure comparison method
Loading condition
A material used for 140,000 hours
A virgin material
Figure 3.4.3-15: Relation between the Fatigue Damage Rate and the Maximum Microscopic Crack Length
291
(2) A technique by means of hardness measurement
(i) The hardness-measuring method (1)(12)
For high-temperature, low-cycle fatigue, the fatigue damage rate is obtained from the measurement of hardness
making use of the relationship between the rate of the hardness after deterioration against that of the aged material
and the fatigue damage rate.
(ii) The method of using hardness measurement together with analytical calculations (1)(13)
In the same manner as that of the creep damage assessment, this method assesses the fatigue damage rate by
means of the low-cycle fatigue characteristics obtained from the hardness of an area that received thermal aging
(the absolute value of hardness), as well as by means of analytical calculations.
3.2.3 Embrittlement
(1) The polarization method (1)(12)(15)(16)
The polarization method assesses the degree of embrittlement by means of the relationship between the voltage
and the current (polarization curve) appearing when electrolysis is caused in the electrolysis solution using a part
whose embrittlement is to be calculated as the anode, as well as by means of the phenomenon where the natural
electric potential varies according to advancement of embrittlement.
Photo 3.4.3-6: A Device for Remaining Life Assessment of the Rotor Center Hole [MACH-I]
Figure 3.4.3-17(1)(18) shows the result of remaining life assessment of a high- and medium-pressure outer wheel
casing. (The cumulative operation hours is about 160,000 hours, the number of starts and stops is 370, and the
temperature of the part to be assessed is 538°C.)
292
[1]Operation history
Number of starts and stops: 370 Operated time: 161,000 hours Steam temperature: 538°C
Fatigue damage φf
cracks may occur the life assessment
It had been predicted that a crack would have occurred at the R portion of the base part of the main steam pipe
and the re-heated steam pipe on the outside surface of the lower wheel casing due to accumulated creep damage.
And a crack that was considered to be the result of the formation and combination of voids was detected during
the inspection carried out the following year.
Figure 3.4.3-18(1)(19) shows the results of a creep rupture test of a specimen taken from a place very near a
corner of the steam chest where accumulation of creep damage was predicted to have reached almost cracking
point and of observation of the creep point of the place under discussion. The specimen was obtained from a
main stop valve (subjected to about 90,000 hours of accumulated operation hours, about 800 starts and stops,
and a temperature of 566°C at the assessed place) dismantled for the study. The creep damage experienced in the
creep rupture test was near to the predicted damage, and the fact that the creep points had already been combined
to make a minute crack verified that the predicted value was correct.
The data of
the R portion of
the steam chest
(Combined voids)
(The initial
stage) The creep
damage rate and
A void is
the creep strain
formed
(an image
on the
replica).
Figure 3.4.3-18: Situation of the Creep Damage Rate, the Creep Strain, and the Void
293
3.4.3.2 Heat Exchangers
1. Outline
Various kinds of heat exchangers are used in thermal power plants. In this chapter, we discuss measures for
improvement including a new technology to enhance future reliability of the major types of heat exchangers.
Table 3.4.3-3 shows the main failures that occurred to the condensers, the feed water heaters, the cooling water
coolers, the oil cooler and the gland steam condensers due to their aged deterioration, as well as the content of
improvement and countermeasures. For typical examples among them, causes and their countermeasures are
explained below.
Table 3.4.3-3: Improvements of the Plant Equipment and Countermeasures against Malfunctions
Improvements of such major heat exchanging equipment as the condenser, the feed water heater, the oil cooler, the
cooling water cooler, and the gland steam condenser and countermeasures against major malfunctions
Name of Maintenance, Inspection, Improvement, and Replacement Method of
Improvements and Countermeasures
Equipment Item Purpose Inspection
Replacement of the cooling pipes with
(1) Replacement of the Prevention of leakage due to aged new ones
cooling pipes with new deterioration, enhancement of performance ET
ones and reliability Replacement of the cooling pipes with
titanium ones
(2) Improvements of the Reinforcement of temperature-proof (1) Converting the base to a thermal
base exposed to high capability (To prevent cracking due to aged PT sleeve type
temperature deterioration) (2) Reinforcement of the welded part
1. Condenser (3) Improvements of other Countermeasures against wall thickness PT Increasing the wall thickness of the
drains and the steam inlet reduction in the baffle and some others due to
DI eroded part
base erosion caused by aged deterioration
(4) Total inspection of the Inspection as to whether or not erosion, VI
inside of the condenser corrosion, or cracking occurs on the internal Repairing the damaged part
body structure due to aged deterioration PT
(5) Replacement of the Maintaining airtightness of the condenser HT Replacement of the joint with a new
rubber belt expansion joint (Prevention of cracking due to aged
VI one
with a new one deterioration)
(1) Measures to prevent
(1) Prevention of ammonium attack
ammonium attack Replacing the heating pipes with new
(2) Prevention of erosion due to steam and ET
(2) Replacement of the stainless pipes
2. Low- drain attack
steel pipes with new ones
pressure Feed
water Heater (3) Inspection of the parts
installed inside the body Checking whether or not erosion or wall VI
Replacing the set with a new one
and the inside of the body thickness reduction occurs UT
plate
(1) Improvement of the structure of the water (1) Improvements of the structure of
chamber the water chamber
(1) Improvement of the (a) Prevention of leakage and sudden gush (a) Adoption of a new welding method
structure of the water from the welded part at the pipe end PT for the pipe end
3. High- casing and checking of Prevention of cracking at the pipe end (b) Increasing the corner R of the
pressure Feed inlet attack in the steel (b) Prevention of cracking due to stress water chamber
water Heater pipes concentration on the corner of the water PT (c) Installing a tube-inserted pipe
(2) Adhering of scale to the chamber Totally replacing the existing water
steel pipes (c) Prevention of the end of the heating pipes chamber with a new one in which the
VI above improvements are integrated
from being eroded
(2) Prevention of scale adhering VI (2) Effecting water jet cleaning
(1) Measures against aged deterioration (1) Replacement of the pipe nest with
(1) Replacement of the
a new one
pipe nest with a new one (2) Recovering of function and performance ET
4. Oil Cooler (2) Installation of a cover that is to be
(2) Modification of the (3) Simplification of maintenance and VI
tightened by flanged bolts on the water
water chamber inspection chamber
(1) Measures against aged deterioration (1) Replacement of the cooler with a
(1) Replacement of the
new one
5. Cooling cooler with a new one (2) Recovering of function and performance ET
Water Cooler (2) Installation of a cover that is to be
(2) Modification of the (3) Simplification of maintenance and VI
tightened by flanged bolts on the water
water chamber inspection chamber
(1) Replacement of the blower with a
(1) Replacement of the new one
(1) Measures against aged deterioration of
6. Gland blower with a new one
the impeller shaft (2) Installation of the blower in a
Steam (2) Modification of the VI
(2) Measures to prevent vibration of the separate place
Condenser blower to a separately
blower (3) Modification of the distribution
placed type
valve located around the blower
Meaning of the acronyms: ET (Eddy Current Flaw Detection Test) PT (Penetrate test) DI (Dimension Inspection) VI (Visual Inspection) HT
(Hardness Test) UT (Ultrasonic Flaw Detection Test)
2. Technology for Preventative Maintenance and Measures to Strengthen the Deterioration-proof
294
Capability of the Condensers
2.1 Corrosion of the Cooling Pipe
Aluminum-brass pipes have been traditionally used for the cooling pipes of condensers. Inlet attack and
deposit attack (the impingement attack) are corrosive and erosive attacks from the inside of the pipe.
Ammonium attack is a corrosive and erosive attack from the outside. In particular, corrosion and erosion from
the inside, such as deposit attack, can sometime pierce the wall in a short time to cause water leakage.
Such measures as the injection of iron sulfate, electrochemical protection, the injection of chlorine, ball purge,
and counter flow washing are traditionally taken to prevent corrosion and erosion from the inside, but additional
daily elaborate operation control is also important.
A periodical E.T. (eddy current flaw detection test) is effective as preventative maintenance for aluminum-
brass pipes. And nowadays, automatic control is adopted to arrange the data of the E.T. in order and to control
the remaining wall thickness.
Recently, there is a tendency to take the safety measure whereby all aluminum-brass pipes of a condenser
already installed are replaced by titanium pipes. The merit is a great reduction in the risk of seawater leakage
and the omission of the E.T. to be effected at periodic inspection and daily maintenance to protect the cooling
pipes. On the other hand, it becomes necessary to shorten the space between the cooling pipe supports as a
vibration-proofing measure so that titanium pipes with thin wall thickness can be used because titanium is
somewhat inferior to aluminum-brass in terms of heat conductivity.
Table 3.4.3-4 Damage to the Base Portion of the Condenser Exposed to High Temperature and Examples of
Their Countermeasures
Damage situation of the base portion of the condenser exposed to high temperature and examples of the
countermeasures in the shape of the base
Plant Shape of the Base
Output Time of
Operation Name of the
No. (at the Damage Damage Situation
Mode Base Original Shape Countermeasures
opening of Occurrence
the plant)
Cracks
High-pressure Seventeen A crack of 105 mm in (hatched area)
250 MW Drain years after the body and another
1 DSS
(1967) Manifold the operation crack of 30 mm in the
(150 A) started nozzle Fillet welding
Cracks
Medium- Twelve A crack of 115 mm in (hatched area)
250 MW pressure Drain years after the body and another
3 DSS The thermal sleeve
(1974) Manifold the operation crack of 70 mm in the
(100 A) started nozzle Fillet welding
Cracks
At a constant Nineteen (hatched area)
SSR steam
350 MW load years after A crack of 178 mm in
4 inlet Groove
(1970) (entered in an the operation the body welding
(150 A)
emergency) started Fillet welding
Three cracks of 80
Cracks
mm max. length in the
Turbine Lead Ten years
peripheral direction
600 MW At a medium Pipe Drain after the
5 occurred on the
(1973) load Inlet operation
welded part of the
(50 A) started
thermal sleeve and the
body
Meaning of the acronyms: DSS (Daily Start-Stop) WSS (Weekly Start-Stop) SSR (Steam Seal Regulator)
Cracking can be prevented by the countermeasure where the hot side, the nozzle, and the cold side, the body,
are connected through the thermal sleeve and the point of injection is chosen so that the hot fluid does not point
the body to relieve steepness of the temperature gradient between the nozzle and the body.
295
3. Technology for Preventative Maintenance and Measures to Strengthen the Deterioration-proof
Capability of the Feed Water Heater
3.1 Inlet Attack of the Steel Pipes
Inlet attack is a phenomenon where the protective film on the inside surface of a pipe is destroyed and eroded
by water flow, and it is often seen in high-pressure feed water heaters whose temperature of feed water is as high
as between 150°C and 200°C. Erosion and corrosion due to the influence of the pH and temperature of the feed
water are the causes besides vortices and too high a velocity of the fluid flow.
= Countermeasures =
Installation of an inserted pipe and a flow-smoothing bell mouth as illustrated in Figure 3.4.3-19 are effective.
Leakage
An inserted pipe
An inserted pipe
(SUS304TB)
(SUS304TB)
A flow-smoothing bell mouth A flow-smoothing bell mouth
(1.25Cr0.5Mo Steel plate) (1.25Cr0.5Mo Steel plate)
= Countermeasures =
Such measures as periodical removal of scale, complete protection against rusting during storing of the unit in
the case of suspension of operation, complete control of water quality when the unit is restarted, etc. can be
countermeasures. Water jet washing and blast washing are usually used for the mechanical removal of the scale,
and acid washing with monoammonium citric acid is used for the chemical removal of the scale. The former is
superior in terms of cost, while the latter is superior in terms of removal performance.
= Countermeasures =
To keep the space between the main body and the row of the pipes so that the local flow speed of heating
steam does not become too fast, adopt an arrangement or location of the nozzle that prevents the heating steam
and the wastewater from interfering with each other. In addition to this measure, utilization of stainless pipes for
two or three outside rows is also effective.
= Countermeasures =
Replace some of the tubes located where any parts are liable to receive ammonium attack by stainless pipes
that have good corrosion resistance. Such measures as modification of the structure so that gas does not stay
around parts from where non-condensed gas is extracted or a change of operational parameters such as setting of a
vent amount also deserve consideration.
296
3.5 Non-destructive Inspection of the Heating Pipe
Carbon steel, stainless steel, aluminum-brass, monel metal, etc. are used for the heating pipe of the feed water
heater. But the necessary frequency and type of inspection vary according to the material used. The necessity
of inspection is high for carbon steel pipes and brass pipes in order to prevent leakage due to corrosion or erosion
of the heating pipe, while the necessity is low for stainless pipes that are highly corrosion resistant.
On the other hand, austenite stainless and copper alloy material that necessitate less inspection can receive E.T.
contrary to no necessity of inspection because they are non-magnetic materials, while checking of damage to such
ferromagnetic materials such as carbon steel pipes by means of E.T. is not so easy.
The following are inspection techniques to be used for the inspection of carbon steel.
Leakage from the heating pipe can also be checked by the opening angle of the drain valve, the drain level, the
temperature difference of the feed water, and abnormal noise. Although it depends on severity of the damage
suffered, the most popular method is to open the water chamber and install stop plugs in the leaking pipe and other
pipes suffering from the secondary damage. It is recommended to replace the feed water heater as a unit when
plugs are installed in 10% of the pipes. Replacing the heating pipes with stainless ones is also an effective
measure.
3.6 Damage to the Diaphragm in the Cylindrical Water Chamber of the High-pressure Feed Water
Heater
There is a structure where a diaphragm is used to obtain water tightness of the water chamber of the high-
pressure feed water heater (Figure 3.4.3-20). In this structure, the high pressure in the water chamber is
supported by a water chamber cover made of a thick plate and is sealed by the diaphragm. The diaphragm is not
often damaged.
The body
The diaphragm
Since there are more cases nowadays where the welded part at the corner of the pipe plate where the partition
plate is attached and the welded part of the covering plate for the γ hole are cracked (fatigue cracking), it is better
to totally modify it.
297
= Countermeasures =
It is required to replaced the diaphragm every two years taking the DSS mode of operation into consideration.
The old one should not be used but should be replaced it with a new one at such an opportunity as opening of the
water chamber when the old one is broken.
3.7 Erosion of the Inside of the Low-pressure Feed water Heater Body
Reduction in the wall thickness of the parts located inside the heater such as the body plate and the pipe-
supporting plate due to aged deterioration has often been experienced recently.
A study revealed that the places where reduction in wall thickness had been experienced are those where the
flow of steam is relatively fast in the heater or places where there was movement of wastewater and where erosion
is liable to be induced. This attack is a phenomenon due to erosion and corrosion occurring in a specific
temperature range.
The corrosion speed of an iron or steel material is greatly influenced by the environmental temperature, and
there is a tendency for a material to increase its corrosion speed at a specific temperature. The number of cases
of the phenomenon where plates inside the body of the low-pressure feed water heater are corroded and their wall
thickness is reduced around the above-mentioned temperature range has increased.
= Countermeasures =
Such measures as padding by welding on the area whose wall thickness has been reduced, backing the area by
a metal stripe and/or partially replacing with a newly fabricated part made of SUS material are effected.
= Countermeasures =
Check whether or not there is any incorporation of wastewater from the upper stream in the piping (e.g., failure
in discharge of the wastewater due to deterioration of the wastewater trap), and take necessary measures to
improve the root of the incorporation if such incorporation exists. Adopt the thermal sleeve-type structure for
the nozzle as shown in Figure 3.4.3-21 in order to relieve the temperature gradient between the piping and the
body-side plate. Also use full welding to avoid the occurrence of stress concentration.
298
3.4.3.3 Pump
Table 3.4.3-6: The Content of the Inspection on the Periodic Inspection of BFP
Item Content of the Inspection
The sliding ring • Clearance
• Cracks (P.T. inspection)
The main shaft • Measurement of the bend
• Cracks (P.T. inspection)
• Measurement of the dimensions of the gland and the journal
Rotating • Visual inspection
Component Corrosion, Abrasion, Fretting, Threads on the shaft, Key way
The impeller • Dimensions and run-out of the sliding part
• Scale
• Cracks (P.T. inspection)
• Visual inspection
Cavitation corrosion, Abrasion, Erosion, Dents, Movement
The outer body • Erosion of the inside surface
• Cracks in the stainless padding (P.T. inspection)
• Dimensions of the joint part and scratches on the surface
• Damage to and abrasion of the threads of the tightening bolts
The inner body • Erosion of the mating surface
Casing • Scale
• Cracks (P.T. inspection)
• Damage to the mating surface of the joint to the outer body
• Loosening of bolts
• Scratches and cracks
• Inner body bushing/Erosion of the water extraction pipe/Deformation
The radial metals • Contact
• Clearance
• A crack in and separation of the padding metal (P.T. inspection)
Bearing
The thrust metals • Abrasion of the thrust shoe and the disk
• Damage
• Checking of the thrust shoe movement
Others • Checking of the end play of the rotating components
• Alignment check after dismantling and assembling
299
Table 3.4.3-7: The Content of the Inspection on the Periodic Inspection of CWP
Item Content of the Inspection
The main shaft (1) Measurement of the bend
(2) Dimensions of the outside diameter of the bearing sleeve
(3) Dimensions of the gland gasket sliding sleeve
(4) Visual inspection
Corrosion/Cracks/Abrasion/Looseness of the key/Bolt hole
The impeller (1) Measurement of the outside diameter of the wearing
(2) Visual inspection
• Corrosion
Rotating
• Cracking
Component
• Dents/Contact of the tip of the vane with the liner
• Abrasion of the base of the vane entrance
• Looseness of the key/Contact of the joint part
(3) Cracking in the boss and the base of the vane (P.T.)
The coupling cover (1) Visual inspection
Corrosion (the general part/the flange surface/the portion for the O-ring)
The shaft sleeve (1) Visual inspection
Corrosion (the general part/the joint/the portion for the O-ring)
1. The bearing (1) Dimensions of the internal diameter
(2) Visual inspection
• Deterioration of the rubber
Bearing
• Boundary separation of the rubber from the shell
2. The shaft case (1) Visual inspection
Corrosion (the spigot joint/the boundary between the case and the shaft shell)
1. The pumping-up (1) Visual inspection
pipe of the Corrosion (the spigot joint on the flange surface/the general part)
discharging body
2. The stuffing box (1) Visual inspection
Corrosion (the spigot joint on the flange surface/the gasket inserting part/the general
Casing part)
3. The suction bell for (1) Dimensions of the internal diameter of the liner ring
the guide vane (2) Visual inspection
Corrosion (the shaft case inserting part/the joint portion with the vane entrance tip
and the inner pipe/the spigot joint on the flange surface/the general part)
Table 3.4.3-8: Measures Taken to Strengthen the Deterioration-proof Capability of the Boiler Feed water Pump at
Hitachi, Ltd.
Phenomenon that
No. Cause Measures for Improvement
Occurred
c Cavitation erosion Increased operation time in the low flow • Padding of a corrosion-resistant metal on the first-
rate range due to increased opportunity of stage impeller
intermediate-load-range operation such as • Improvement of the shape of the inlet channel and
DSS and WSS the first-stage impeller
d Increased vibration Unbalanced force vibration due to locking • Adoption of a diaphragm coupling with better
of the tooth flank of the gear coupling flexibility
caused by a sudden change in the load
e Increased vibration Increased operation time outside the • Adoption of rotors with high rigidity
designed flow rate due to increased
opportunity of intermediate-load-range
operation such as DSS and WSS
f Damage to the shaft Fatigue started from corrosion pitting • Detailed inspection of the shaft and removal of
caused by deterioration of feed water corrosion pits
quality due to leakage of seawater or a
certain other reason.
g Occurrence of self- Increased clearance due to aged • Adoption of a vibration-damping-type balancing
excited vibration deterioration drum
h Corrosion damage Deterioration of the corrosion-proof • Replacing the current one with the new one to which
to the chrome environment due to increase in DO in the improved corrosion-proof chrome plating is applied
plating feed water caused by CWT operation • Improvement by adoption of a material not
necessitating chrome plating (adoption of a shaft
without chrome plating/a shaft seal part without
chrome plating)
i Damage to the part Too much stress due to thermal deformation • Replacing the current casing with a new one whose
where stress was of the casing repeatedly working on it when deterioration-proof capability is strengthened
concentrated the turbine is started and stopped • Changing the control method to temperature control
from the seal water control to prevent too much cold
water from flowing in
j Erosion of the inner Erosion corrosion caused by aged • Applying padding of austenite stainless steel after
surface of the deterioration of the material and developed effecting welding of carbon steel for the repair
discharging nozzle under an environment where there is steam
with high-speed flow
301
Table 3.4.3-9: Measures Taken to Strengthen the Deterioration-proof Capability of the Circulating Water Pump at
Hitachi, Ltd.
Phenomenon that
No. Cause Measures for Improvement
Occurred
c Reduction in wall Crevice corrosion due to seawater • Adoption of a corrosion-proof technique to coat the
thickness of the Aged deterioration of the material inside surface in contact with water with a ripoxy
loose flange due to lining
corrosion
d Corrosion of the Crevice corrosion due to seawater • Adoption of a technique to prevent seawater from
mating surface of Aged deterioration of the material penetrating by means of epoxy resin putty filled in
the intermediate the joining surface
coupling
e A malfunction of Clogging due to adhering of marine • Adoption of seal-waterless bearings
feeding of the seal creatures and accumulation of adult
water creatures in the feed water piping and the
Abrasion of the feed water channel in the pump
shaft-sealing device
f Corrosion of the Crevice corrosion due to seawater • Adoption of a corrosion-proof technique to coat the
flange surfaces of Aged deterioration of the material inside surface in contact with water and the flange
the bearing bracket surface with a ripoxy lining.
and the column pipe
g Corrosion of the Crevice corrosion due to seawater • Strengthening corrosion-proof capability by
bolts, the nuts, and Aged deterioration of the material applying a crevice corrosion inhibitor (RFC)
some others
h Reduction in wall Crevice corrosion due to seawater • Effecting a periodic assessment of corrosion by
thickness due to Aged deterioration of the material means of an ultrasonic test
corrosion of such
parts as the casing,
the column pipe, etc.
i Leakage of oil in the Crevice corrosion of the part of the variable • Neutralizing the possibility of oil leakage by
impeller boss (only pitch vanes due to seawater adopting oil-less bearings for the variable pitch
for the circulating control mechanism for the vane to eliminate the
water pump for the necessity of boss oil.
rotating vanes)
302
4. Assessment Techniques for Equipment
4.1 Assessment Techniques at Mitsubishi Heavy Industries, Ltd.
The following are explanations of the assessment techniques for the area of components that are possibly
subject to fatigue taking remaining life assessment of the outer casing as an example to prevent escalation to
secondary damage to other equipment than the boiler feed water pump in the event of failure.
Figure 3.4.3-22: A Structural Drawing of the Feed water Pump of the Mitsubishi MDG 267 Boiler
This life assessment method(Figure 3.4.3-23) is an analytical method, and they are studying the replacement of
the component when cracking due to fatigue has occurred, development afterwards, and when the maximum
allowable depth of a crack has been reached.
allowable depth
Stress analysis Max. allowable crack
depth according to the
crack development
curve for stainless steel Number of Starts
(Cracking in NDI) Remaining Life and Stops N
Predicted future
operation mode
Remaining life
assessment
Even if such a crack is found in the periodic inspection and repaired by means of welding, its deterioration
resistance capability would not be high enough and cracking would recur and continue its development. For safe
operation of a plant, it is recommended as the measure to strengthen the deterioration-proof capability of the pump
that “occurrence of cracking” should be deemed the end of its life.
303
Consumed
Part Name Name of Portion Remaining Life
Fatigue Life
The seating surface for the outer
casing suction-side gasket
1. The corner area More than
4.0%
(the suction nozzle side) 30 years
The suction nozzle
304
3.4.4 Corrosion of Steam Turbines and its Countermeasures
The conditions inside a steam turbine continuously change from high temperature and high pressure to a
pressure lower than atmospheric pressure and low temperature depending on the conditions of steam.
For a recent typical power plant, the steam temperature at the inlet of the turbine is about 540°C to 570°C, the
pressure is about 250 kgf/cm2 and the exhaust gas temperature is about 30°C.
The change in steam conditions agrees with improvement of the materials used for each part of a turbine and
of the turbine structure. Development of heat resistant materials having great strength at high temperature is
indispensable to achieve high efficiency in power generation.
The design of a steam turbine is usually achieved for the high temperature section and the low temperature
section separately. Table 3.4.4-1 shows typical materials used in each section of a steam turbine. Low alloy
steel containing a low percentage of chromium and molybdenum is used for the rotor, the casing, the steam valve
and the tightening bolt all of which are used in the high and medium pressure section. And low alloy steel that
has high tensile strength such as 3.5NiCrMoV steel is used for the low pressure rotor. In this material, chromium
contributes to the oxidation resistance and resistance to the graphitization, and molybdenum contributes to the
high temperature strength. The 12Cr heat resistant steel is used for the rotor, the blade, the nozzle and the bolt all
of which are used in the high and medium pressure section. For the material for the rotor whose temperature
increases to about 580°C, 12Cr steel reinforced with molybdenum and vanadium is used with tantalum and
niobium or nitrogen added and with fine carbide and nitride precipitated. For use in the higher temperature,
strength at the high temperature is improved by the addition of tungsten or molybdenum.
12Cr-Mo-V-W-Nb-N steel
The blade 12Cr-Mo-V-W steel
The nozzle 12Cr-Mo-V-Nb-N steel
12Cr steel
Ni-based superalloy
The casing 1Cr-1Mo-V steel
The steam valve 1Cr-0.5~1Mo steel
11/4~21/4Cr-0.5~1Mo steel
12Cr steel
The tightening bolt 1Cr-1Mo-V steel
12Cr-Mo-V-W steel
12Cr-Mo-V- Nb-N steel
Ni-based superalloy
The rotor 3~3.5Ni-Cr-Mo-V steel
Low pressure turbine
With no treatment
Erosion Rate (%)
With boronization
treatment (thickness of
the surface layer: 80µm)
Time (h)
Figure 3.4.4-1: Erosion Resistance of the Nozzle Plate with Boronization Treatment
306
3.5NiCrMoV steel
Figure 3.4.4-2: Influence of Cl- Concentration on Behavior of Various Types of Steel Related to SCC
For the 3.5 NiCrMoV steel, pitting occurs at 100 ppm of a Cl- concentration and SCC with 1000 ppm of a Cl-
concentration. While, for 12Cr steel and 17-4PH steel, no SCC occurs when Cl- is increased up to 1000 ppm.
SO42- has so little acceleration function compared with Cl- that no SCC occurs when the Cl- concentration is
increased up to 1000 ppm though pitting occurs at the same Cl- concentration. And for Na+, neither pitting nor
SCC occurs up to 1000 ppm of Cl- concentration. However, the SCC occurs both in 12Cr steel and 17-4PH steel
where the concentration is as high as 10% at a temperature of 200°C or higher.
Thus, we show the influence of dissolved oxygen. Figure 3.4.4-3(12) shows the situation in the case of
3.5NiCrMoV steel. This test was conducted in conditions such as a temperature of 90°C, a Cl- concentration of
10 ppm and range of dissolved oxygen concentration between 7 ppb or less and 1.63 ppm. The test results show
that the SCC occurs when the dissolved oxygen concentration exceeds 10 ppb and 10 ppm Cl- concentration.
Our results showed that the SCC sensitivity to the dissolved oxygen has the same tendency as that of the low alloy
steel as shown in Fig. 3.4.4-4(12) in the case of 12Cr steel used in the material for blade, but the speed of crack
development is slow. And the SCC resistance of the 17-4PH steel is more superior than the two types of steel
mentioned above as shown in Fig. 3.4.4-5(12).
Figure 3.4.4-3: Influence of Dissolved Oxygen Concentration on Behavior of 3.5NiCrMoV Steel Related to SCC
Figure 3.4.4-4: Influence of Dissolved Oxygen Concentration on Behavior of 12Cr Steel Related to SCC
307
1000 hour test
1500 hour test
3000 hour test
Figure 3.4.4-5: Influence of Dissolved Oxygen Concentration on Behavior of 17-4PH Steel Related to SCC
Temperature (°C)
Figure 3.4.4-6: Influence of Temperature on Corrosion Fatigue in NaCl Aqueous Solution
Recently, the method of feedwater treatment in thermal power plants is being changed to CWT (treatment by
oxygen) from conventional AVT. Some of the power plants have adopted the CWT. Influence of this change in
water treatment to the material of turbine is being investigated and no significant difference in the fatigue strength
of 3.5NiCrMoV steel and 12Cr steel has been found in any conditions of AVT (pH9.5, 7 ppb O2) and CWT (pH8.0,
[I] 50 ppb O2 and [II] 200 ppb O2) according to Fig. 3.4.4-7(15).
Repeated number at which the material is broken Repeated number at which the material is broken
308
3.4.5 Corrosion of Heat Exchangers and Piping of Turbine Systems and its Countermeasures
3.4.5.1 Introduction
The system configuration of a thermal power plant using steam turbines has become more complicated due to
improvement in the steam condition and increase in the capacity of a single unit. Figure 3.4.5-1 shows as an
example the main system diagram(1) of a power plant having steam turbines of the 1000 MW class. The main
facilities of the power plant are classified as follows.
(1) The turbines and generators
(2) The water treatment unit for water for the condenser and feedwater
(3) The condenser unit
(4) The feedwater heater unit
(5) The feedwater pump
(6) The piping unit for each component system
Approximately
3000 tons/h
The generator
The
condenser
pump
The turbine
The
demineralizer
for the
condenser
Approximately
280°C Gland steam
deaerator
condenser
The
Among these main facilities, equipment and components, of which corrosion is one of the main concerns, are
the low pressure turbines, the condenser in the condensing and water feeding system, the deaerator, the feedwater
heater and the piping, all of which are placed under wet conditions during operation of the turbine, is well as other
components and piping that utilize seawater for cooling fluid, all of which handle or use water. In this chapter,
we discuss corrosion occurring in the heat exchanger and the piping for the turbine system and also its
countermeasures.
3.4.5.2 Examples of Corrosion Occurring in the Heat Exchangers and the Piping used in the
Turbine System and its Countermeasures
1 The Heat Exchangers Used in a Power Plant Using Steam Turbines
1.1 The Condenser
Figure 3.4.5-2 shows types of corrosion occurring in the condenser cooling pipes and protective measures
against it(2).
309
Type of corrosion and leakage Protective measures
Figure 3.4.5-2: Corrosion and Leakage of Condenser Cooling Tube and Its Countermeasures
Here in this chapter, we introduce the types of corrosion occurring in the cooling pipes facing the outside
(steam side) and the protective measures.
310
The low pressure turbine
A group of the
Eroded portion
cooling pipes
Eroded portion
Figure 3.4.5-3: Erosion of the Outer Surface of a Condenser Cooling Pipe (at a place where erosion occurs)
311
The cross section of
the protection element
The supporting plate
A bundle of pipes
The protection pipes
Figure 3.4.5-5: Prevention of Droplet Erosion by Installation of Pipes to Protect the Peripheral Portion of the
Bundle of Pipes
1.2 Deaerator
In some cases, the inner surface of the deairing chamber body is partly damaged in a plant where the pH of the
boiler feedwater is smaller than 9.0 and the water includes a relatively large amount of dissolved oxygen. The
area receiving the damage is limited to the area on which the feed water drops from the deairing tray or against
which the dropping water is blown by the influence of heating steam. The cause of the damage is erosion
corrosion caused by the feedwater that drops from the deairing tray, is accelerated by heating steam entering from
the bottom center part of the tray which directly collides with the deairing chamber body. And when there is a
certain distance between the deairing tray and the body wall, erosion corrosion is sometimes caused by free fall of
the feedwater regardless of the existence of the heating steam.
Figure 3.4.5-6 shows an example of the damage. The protective plates made of stainless steel having strong
erosion corrosion resistance are attached to the inner surface of the deairing chamber body as shown in Fig. 3.4.5-
7 to prevent erosion corrosion damage of the deairing chamber body.
Deaerating chamber
The tray
Heating steam
Erosion
Figure 3.4.5-6: Example of Corrosion Inside the Main Body of the Deaerating Chamber
312
The deairing chamber
The tray
Heating steam
Figure 3.4.5-7: An Actual Measure Against Erosion of the Inner Surface of the Deairing Chamber Body
(i) Pitting
When pitting occurs, it occurs almost evenly along the entire length of the cooling pipe, and the speed of
progression is of such an extent that the pitting pierces the wall with a thickness of approximately 1.2 mm in about
6 months in the fastest case. There is a special tendency whereby pitting is liable to occur more in the cooling
pipes of a spare unit fully filled with water than in the pipes through which water is running.
It is considered that the following combination of factors is the cause of the pitting.
1) The corrosion inhibitor added in the cooling water is not effective in corrosion prevention, or the
concentration of the corrosion inhibitor is insufficient.
2) A corrosion factor exists in the cooling water.
3) Local electric potential difference or difference in the concentration of dissolved oxygen is liable to
occur because the liquid in the pipe has almost no velocity when the operation is suspended (in a
stand-by situation).
4) Dissolved oxygen is consumed by microbes to make the atmosphere anaerobic, and the pipe is
corroded by ionized sulfur produced due to the propagation of sulfate salt reduction bacteria.
Photo 3.4.5-4: Stress Corrosion Cracking in an Aluminum-brass Pipe Dipped in the Cooling Water.
313
2 Piping for the Turbine Plant
2.1 The Steam Pipes
The damage to a main steam pipe or a hot reheat steam pipe is creep damage caused by the effect of internal
pressure during the steady operation and erosion and low cycle fatigue damage due to repeated thermal stress
caused by load fluctuation due to start and stop or some other factors.
Places where wall thickness reduction is liable to occur are the main stop valve (MSV), the governing valve
(CV), the lower outlet of the drain valves located before and after the valve seat of the combined stop and control
reheat valve (CRV), the elbows, the caps and the orifices. Leakage due to reduction in the wall thickness was
experienced in these places and components. Figs. 3.4.5-8 and 3.4.5-9 show the location of the damage and the
actual damage to the drain pipe elbows before and after the valve seat of the CRV, and the actual damage to the
main steam lead pipe warming orifice, respectively.
Figure 3.4.5-8: An Example of Damage to a Drain Pipe Elbow Before and After the Valve Seat of the MSV Valve
Erosion
casing
To the condenser
Oxidized
powder scale
Erosion
To the condenser
Leakage
Figure 3.4.5-9: An Example of Damage to the Main Steam Lead Pipe Warming Orifice
These types of erosion are caused by the collision of the drain jet and flowing- in of the oxidized scale existing
in the main pipe. The countermeasures are periodic measurement of the wall thickness of the places in the
system where reduction in wall thickness is liable to occur and replacement of those components for which
reduction in wall thickness has been advanced.
And the orifice used to be replaced by one that had a shape more favorable in terms of erosion resistance.
Temperature: 158°C
corrosion (mg/cm2)/14 days
Ni-Cr-Cu steel
Cr-Mo steel
314
Reduction in weight due to erosion
Temperature: 171°C
Velocity: 200 m/s
Ni-Cr-Cu steel
Cr-Mo steel
Temperature: 150°C
Velocity: 90 m/s
Wetness fraction: 11%
: Carbon steel
Reduction in weight due to erosion
: Cr-Mo steel
Velocity: 90 m/s
Wetness fraction: 11%
corrosion (mg/cm2)
O2 concentration:
16 ppm
In the case of carbon steel, reduction in weight increases in proportion to the square root of the steam speed,
and rapidly increases with wetness fraction up to approximately 7%. But the increase rate in the reduction
becomes very slow even when the wetness fraction increases. And the reduction in wall thickness tends to
decrease with the increase in the amount of alloy elements in the material. In the case of a low alloy steel, the
reduction in wall thickness is not much affected by the wetness fraction or steam speed. As for the influence of
temperature, there is a tendency for the amount of reduction in wall thickness to become its maximum in a certain
range of temperature (around 180°C) and to decrease outside this temperature zone either above or lower. This
phenomenon happens because the major dominant factor is the speed of corrosion action in the temperature zone
lower than the temperature at which the speed of reduction in wall thickness reaches its peak while a protective
film of magnetite (Fe3O4) is formed on the surface of the metal in the higher temperature zone. Difference in the
quality of water need not be considered taking into account the difference in speed of the reduction in wall
thickness occurring in each part because the quality of water is controlled according to the requirement of
standard values separately set for the feedwater heater and the boiler. Therefore, the parameters that cause the
difference in speed of reduction in wall thickness are the temperature and the shape of the channel for fluid. The
places and portions where the reduction in wall thickness and leakage were experienced are bends and branches
where the water temperature was between 150°C and 250°C, the outlet of the booster pump for the boiler
feedwater pump (BFP), the curved pipe at the outlet of the BFP, the outlet of the adjusting valve and the outlet of
the orifice.
Photos 3.4.5-5 and 3.4.5-6 show an actual case of reduction in wall thickness occurring in the outlet of the
booster pump for the boiler feedwater pump (BFP) and also another actual case of that occurring in the curved
pipe at the outlet of the BFP, respectively. Erosion corrosion is prevented by means of periodic measurement of
the components and the portions where the reduction in wall thickness is liable to occur and replacement of the
component by a corrosion resistant material such as a CrMo steel pipe or a stainless steel pipe if the reduction in
wall thickness has already progressed.
315
The BFP connecting pipe
Photo 3.4.5-5: An Example of Reduction in Wall Thickness of the BFP Booster Pump
Photo 3.4.5-6: An Example of Reduction in Wall Thickness of a Curved Pipe at the Outlet of the Boiler Feedwater
Pump
The short
pipe
The adjusting valve The reducer
Figure 3.4.5-14: The Typical Piping Form Around the Heater Drain Pipe Adjusting Valve
316
3.4.6 Corrosion in the Equipment of the Seawater System and the Piping and its Countermeasures
3.4.6.1 Preface
Seawater is considered to be a typical substance that produces a strong corrosive environment since it contains
large amount of strong corrosive chloride ions and has high electric conductivity. Therefore, the equipment and
the piping used in a seawater system and their components often suffer from noticeable corrosion damage unless
they are used based on specific technologies of each component and material. This report explains these
situations of damage, their features, and countermeasures.
Concentration of C1- of
seawater equivalent
Temperature (°C)
O: No corrosion S: rusted
P: Pitting C: Stress corrosion crackling
Figure 3.4.6-1: Each corrosion damages on SUS304 stainless steel in solution of neutral chloride
317
The next fact is that high electric conductivity of seawater has an important influence on the occurrence and
progression of corrosion damage. In other words, corroding action caused by an electrochemical mutual action
called bimetallic corrosion (also called galvanic corrosion) occurs when component and materials that have
different corrosion potential from each other (for example, a noble metal Cu and a base metal Zn) electrically
make contact and are immersed in a solution. This phenomenon is corrosion damage that a base metal dissolves
at first (as a sacrifice) against noble metal (anodic dissolution). In this case, higher electric conductivity means a
longer distance over which an electrochemical mutual action can occur. In seawater, where the affected area is
simply calculated as the square of 100 times that in freshwater, the speed of corrosion damage is accelerated
according to the increase in the affected area.
Therefore, special care is necessary to prevent this galvanic action (selection of materials and design of parts
configuration) in order to decrease corrosion damage to hydraulic machines and some others that consist of
various components and materials (1).
In certain cases, the corrosivity feature of seawater environment works moderately to the same degree as
freshwater does depending on the material used and the environmental conditions. On the other hand, cautious
observation is required because it is not unusual for a new kind of corrosion phenomenon to appear, greatly
increasing the speed of corrosion propagation and often leading to severe corrosion damage when the
environmental conditions change or a particular material is used(6)(7).
The casing
(Carbon steel coated heavy corrosion control)
rubber bearing
Level of seawater
shaft casing (SUS316)
shaft (SUS316)
Figure 3.4.6-2: Structure of a Vertical Shaft-type Seawater Pump and Examples of Materials Used in the
Components
Such local corrosion as indicated below likely occurs in seawater that contains a high concentration of chloride
ions although stainless steel is used for various parts as shown in the figure. We explain the corrosion damage
listed below and countermeasures.
(1) Pitting
(2) Crevice corrosion
(3) Selective corrosion along metallographic structure
(4) Intergranular corrosion
(5) Stress corrosion cracking and hydrogen embrittlement cracking
(6) Cavitation erosion
(7) Corrosion fatigue
318
1.1 Pitting Damage and its Countermeasures
Figure 3.4.6-3 shows the relationship between the chemical composition of various kinds of stainless steel that
have been immersed in seawater in Japan for three years and the maximum depth of pitting. It is understood that
the depth of erosion is very thin and that it takes considerable time for a large-sized hydraulic machine made of a
thick plate to be corroded although it depends on the metallographic structure and the alloy composition.
1 2 3 yr
γ type
α type
Two phase type
Figure 3.4.6-3: Relation between the Pitting Index of Various Stainless Steels Dipped in Actual Seawater and the
Maximum Pitting Depth
However, it is necessary to be careful when seawater is polluted. Figure 3.4.6-4 (a) and (b) show these
examples. Figure 3.4.6-4 (a) shows that the pitting potential (the critical value of the electric potential to cause
pitting) is reduced by some hundreds of mV and makes the material more liable to be corroded when
concentration of hydrogen sulfide in seawater increases. In the result, the average corrosion rate under this
environment is found to rapidly increase with the increase the concentration of hydrogen sulfide.
Seawater
50°C
pH: 5.5
Flow speed: 40 m/s
Average Corrosion Rate (mm/y)
Concentration of Hydrogen Sulfide (ppm)
SUS316
Seawater
Dissolved oxygen:
Open to atmosphere
pH: 4.8
(a) Relation between Concentration of Hydrogen Sulfide and (b) Relation between Concentration of Hydrogen
Fluid Temperature regarding Pitting Electric Potential Sulfide and Average Corrosion Speed
Figure 3.4.6-4: Corrosion Behavior of Stainless Steel in Polluted Seawater Containing Hydrogen Sulfide
Although natural seawater containing such highly concentrated hydrogen sulfide does not actually exist, it
implies that such severe corrosion damage can occur in the event that formation of a local polluting environment
due to attachment and decomposition of marine creatures or a micro-polluting environment due to dissolution of
non-metallic impurities such as MnS in the steel occur.
For parts with thin wall thickness, it is very necessary to use the high-quality steel indicated above. For the
condenser pipes, the two-phase stainless steel SUS329J1 or the recently developed super stainless steel
SUS329J4L is used (12)(13).
319
1.2 Crevice Corrosion Damage and its Countermeasures
Crevice corrosion occurs not by chemical components in the seawater but also crevices that play an important
role in the starting point of the corrosion.
We have experienced crevice corrosion damage from which seawater hydraulic machines have suffered at the
places shown in Figure 3.4.6-5 (14).
Crevice corrosion
Gravity
The
impeller
Crevice
corrosion
A bolt Sediment
Crevice corrosion
A shaft
Marker paint
Pitting
Figure 3.4.6-5: The places of a Structure Made of Stainless Steel Used for a Seawater Pump Where Pitting
Corrosion Occurred
1) For the impellers of pumps with a lot of downtime, dust is accumulated at the lower part by the force
of gravity and becomes the starting point of corrosion.
2) For bolts in hollow parts, mats made from marine creatures have accumulated and become the starting
point of corrosion as (1) above.
3) When a part number is written on the shaft by a marker, the ink film becomes a crevice and occurs
crevice corrosion.
4) For pump shafts of pumps with a lot of downtime, corroded pone occurs at the point of a lot of floating
dust floats in the zone of the tide.
In these cases, the degree of corrosion damage is so small as to seldom cause a functional problem even in
long-time operation.
Thus, the occurrence of crevice corrosion strongly depends on the structure of the crevice and existence of
attached substances.
The next matter to be discussed is the influence of environmental conditions on the crevice corrosion shown in
Figure 3.4.6-6. The results indicate that the observed maximum corrosion depth increases according to the
increase in the free surface area as well as the DO concentration, and this increase in the amount of cathode action
around a crevice decides the speed of anode action.
Maximum Crevice Corrosion Depth
Concentration of
Dissolved Oxygen
(mm)
Figure 3.4.6-6: Relation between the Outside Free Surface Area and the Concentration of Dissolved Oxygen
Influencing the Maximum Depth of Crevice with crevice corrosion of SUS304 Dipped in Seawater
320
This phenomenon explains that structures where the area of the crevice working as the anode is small but the
area of the free surface working as the cathode is large are liable to suffer severe corrosion damage.
The next exhibit is Figure 3.4.6-7 (15) that shows the condition of metal materials related to crevice corrosion.
In the same manner as that of Figure 3.4.6-3, it indicates that an alloy element (here, the content of Mo)
considerably increases the critical creive corrosion temperature. And the fact that the critical crevice corrosion
temperature is lower than that causing pitting by about 40˚C shall be observed.
Temperature (˚C)
Figure 3.4.6-7: Relation between Critical Temperature of pitting and Crevice Corrosion and Mo Content in
Various Stainless Steels
Next, it explains measures to prevent crevice corrosion. As described above, since crevice corrosion damage
is basically relatively light two-dimensional damage and change over time in depth is slow, it is not necessary to
be overly concerned. However, in the event that a thin material is used or in the case of a part whose air (water)
tightness is critical, it is recommended to see that the structure to prevent dust from adhering, that the device of
the structure is designed so as to prevent corrosion damage from concentrating in a limited area, and that the
appropriate operation is carried out.
Regarding the selection of materials, Figures 3.4.6-3 and 3.4.6-7 should be referenced and Table 3.4.6-1 can be
referenced when there is much freedom of material selection. In other words, the crevice corrosion resistance of
stainless steel is ranked as the lowest, thus utilization of niresist cast iron, or copper alloy is effective when full
corrosivity can be sacrificed to a certain extent.
Table 3.4.6-1: Crevice corrosivity of various materials to use for seawater structures
A paste containing metal zinc grain to prevent crevice corrosion can be available in the market(18).
Application of the paste to crevices in structures can prevent crevice solutions from becoming acidic and can then
suppress crevice corrosion. Also, welding alloy known as prevention of crevice corrosion ressistance.(19).
321
1.3 Selective Corrosion along the Metal Structure and its Countermeasures
First, Photo 3.4.6-1 shows corrosion damage of the threads of a SUS 304 steel bolt and screw used for
seawater hydraulic devices along the non-metallic inclusion. Corrosion dissolution occurs in the shape of many
tunnels along the longitudinal direction of the bolt and the edge is dissolved along Mns non-metallic inclusion.
non-metallic
inclusion
(a) Cross-sectional View of a Stainless Steel (b) An Enlarged View of Portion (a)
Bolt Where Corrosion Occurred
Photo 3.4.6-1: Corrosion Damage on the screw of a SUS 304 Steel Bolt along Non-metallic inclusion
Based on this knowledge, in countermeasures against this kind of damage, it is decided not to use bolt
materials produced through too much rolling and to obsreve the S content where possible. As a result, the
occurrence frequency of damage has been reduced.
Next, we explain the relationship between cutting conditions and corrosion resistance.
The difference in corrosion resistance quality between the best stainless steel and the poorest is a 3-digit
number at maximum even if all of them conform to the JIS standards because the conditions of the formation of
machining-induced martensite phase change greatly depending on the alloy composition and the cutting
conditions.
Figure 3.4.6-8 shows the results of tests where a part of a specimen is dipped in actual seawater for 16 months
in total with the content of Cr as well as the content of Ni changed by a few steps within the JIS standard and also
with the cutting conditions variously changed.
Cumulative Occurrence (%)
Corroded Evaluation
Symbol Material Cutting Conditions
Area Ratio
Fair
Excellent
Good
Based on the above-mentioned knowledge and information, it is understood that the corrosion resistance of
stainless steel dipped in seawater cannot always be grasped only by the average chemical composition but is
strongly influenced by minute impurities, metallographic structure, and attached scale (25).
322
1.4 Grain Boundary Corrosion Damage and its Prevention
Photo 3.4.6-2 shows an example of corrosion damage to a welded part of stainless steel. (a) is for cases
where grain boundary corrosion of an area near to the deposited metal and affected by heat resulted in a hollow
being made, and (b) is for cases where priority dissolution of the deposited metal occurred.
Deposited metal
(a) A Hole Made due to Grain Boundary Corrosion of an Area Influenced by Welding Heat and the Surrounding Area
It is basically important to reduce the influence of heat caused by welding to prevent this damage from
occurring, and using a metal of high quality is not always effective.
Next, information on selective dissolution is presented in Figure 3.4.6-9(29)(30). This figure shows the result of
a test where deposited metal and the base metal of SUS 304 stainless steel were tested in a corrosive environment.
It also shows the fact that the deposited metal is inferior to the base metal over wide conditions of heat treatment
in terms of corrosion resistance. As measures to prevent this damage, cancellation of alloy segregation by re-
solution treatment at 900˚C or higher, utilization of hyper-low C steel to prevent sensitization, or prevention of
alloy segregation by using 9% Mo- or N-added steel are considered effective (29)(30).
Weight Reduction due to Corrosion
{: Deposited metal
U: Base metal
(g/m2/h)
323
1.5 Stress Corrosion Cracking and Hydrogen Embrittlement and Their Prevention
Generally, in our experience, chloride stress corrosion cracking of austenite-group steel does not occur in
seawater at normal temperature.
This material easily cracks due to the rich concentration of magnesium chloride in special seawater
environments where the temperature becomes 60˚C or higher(33) to (35) or in the event that it is exposed to an
oceanic climate in a dry atmosphere whose relative humidity is as low as 30%(36) to (38).
Next, Figure 3.4.6-10(39) and Figure 3.4.6-11(40) show the hydrogen embrittlement of 17-4 PH steel that is used
for the sliding parts of a seawater pump. According to the information obtained from these figures, cracks occur
to materials whose hardness is more than 320 Hv, and the apparent advancing speed of a crack increases more for
steels of higher hardness.
Total specimens
Figure 3.4.6-10: Behavior of the Sliding Part Material Made of 17-4 PH Steel Dipped in 3% Saltwater at Room
Temperature Related to Hydrogen Embrittlement
Lowest Critical Stress Expansion
Constant KISCC (kg⋅f/mm3/2)
Isolated dipping
Figure 3.4.6-11: Behavior of 17-4 PH steel Dipped in the 3% Saltwater at Room Temperature Related to
Hydrogen Embrittlement
Figure 3.4.6-11 shows that a material with higher strength has more crack sensitivity. And crack sensitivity is
higher in the case where the material makes contact with Zn (electrolyted protection) than in the case of isolated
dipping.
Next, Figure 3.4.6-12 shows the influence of environmental conditions on hydrogen embrittlement cracking.
For behavior in this type of cracking, seawater and freshwater are considered to have the same effect. In other
words, pitting at the starting point occurs at first, and then a crack may occur when the dynamic conditions are
satisfied. This point represents a large difference from chloride stress corrosion cracking
Crack Sensitivity Index ISCC
Temperature (˚C)
Considering these findings, it is necessary to recognize the risk that hydrogen embrittlement crack can occur to
very hard stainless steel even under mild environmental conditions if it is hardened too much by attaching to much
importance to smooth movement of the part.
Austenite steel as
a deposited metal
Martensite steel
Cast iron
cast iron
cavitation erosion (mg/2 h)
Reduction in weight due to
Nickel equivalent
Figure 3.4.6-13: Relation between the Amount of Damage due to Cavitation Erosion and Hirayama’s Nickel
Equivalent
325
Figure 3.4.6-13 shows that each curve representing a hardness value of 2~7Cr steel or 13Cr steel shows a
downhill tendency against the Ni equivalent, while each curve representing a hardness value of 18~30Cr-7~20Ni
steel shows a uphill tendency.
This fact makes us recognize that there is a big difference in cavitation erosion resistance among some types of
steel even belonging to the same standard due to even slight differences in their alloy composition.
Therefore, when you engage in the design of an actual hydraulic machine or selection of a material to be used
for repair of damage, you should calculate the nickel equivalent of the material to be used and check the place to
be repaired in the drawing. In some cases, extension of damage life can be expected by a slight change to the
metal composition.
Figure 3.4.6-14 and Figure 3.4.6.15 indicate that it is preferable to choose a material whose strain energy is as
large as possible among types of steel whose corrosion resistance is almost the same.
Amount of damage due to cavitation
erosion (mg/2 h)
Hirayama’s Ni equivalent
Figure 3.4.6-14: Relation between Amount of Damage due to Cavitation Erosion of18Cr-6Co Stainless Steel and
Hirayama’s Ni Equivalent Using the C Content as a Parameter
subjected to a cavitation erosion test (Hv)
Material hardness just under the surface
C content (weight %)
Figure 3.4.6-15: Relation between Material Hardness Just under the Surface Subjected to a Cavitation Erosion
Test of 18 Cr-8Ni and 18Cr-6Co Stainless Steel
326
2 Copper Alloy
Photo 3.4.6-3 shows dezincification corrosion of a part made of brass.
Dezincification
corrosion
Photo 3.4.6-3: Cross-sectional View of Dezincification Corrosion of Brass Part
Table 3.4.6-2 lists the maximum allowable flow speed in a seawater heat exchanger (66). Since the mechanical
strength of the copper alloy surface is weak, it is liable to suffer from erosion damage or impingement attack.
Therefore, the max. service flow speed is approximately 1 m/s or lower for a pure copper pipe and 2 m/s for a
steel alloy pipe.
Table 3.4.6-2: Maximum Flow Speed that can be Used in the Seawater Heat Exchanger Pipe
On the other hand, in the case of a stainless steel pipe, since a slow flow speed (1 to 2 m/s or slower) allows
marine creatures to easily accumulate causing local corrosion, a faster flow speed is preferable if pressure loss can
be ignored.
Pitting of a copper alloy pipe used for a seawater heat exchanger can occur when the seawater is polluted (67).
Injection of ferric sulfate (Fe2+) into seawater whose concentration is brought to 0.01 ppm is considered
effective. The mechanism according to which this works is explained as follows. FeOOH that is produced by
oxidization of Fe2+ is attached to the inner surface of the pipe, forming a protective film there (68)(69).
However, the industry has recently been restrained from using this method in some cases from an
environmental protection viewpoint because the seawater is slightly colored when this method is used. And this
method is not very effective when the seawater is polluted (70)(71).
327
3 Heavy Corrosion Protection Coating and the Lining Parts
3.1 Steel Plates to Which Heavy Corrosion Protection Coating is Applied
Table 3.4.6-3 shows examples of causes of corrosion that occurred to parts to which heavy corrosion protection
coating was applied. This table reveals that the damage was caused in various production processes such as
assembly operation, painting operation, design, and maintenance operation.
Table 3.4.6-3: Causes of Corrosion Damage to Parts in a Structure Exposed to a Flowing Seawater Environment to
Which Heavy Corrosion Protection Coating Was Applied and the Their Classification
It is required to choose such a coating material that will not cause problems in each process (for example, a
material with mechanical flexibility) as shown in the Table 3.4.6-3 in the case where the heavy protection coating
under discussion provides a film thickness of hundreds of µm. Coal tar epoxy paint that is widely used is
considered to be reasonable from a practical viewpoint (70)(71).
328
Table 3.4.6-4: Examples of Methods of Reducing Galvanic Corrosion Damage in a Structure Used in a Seawater
Environment
No. Method Description Actual Case
Isolation of the materials from each a) b)
Coating
other (by means of a spacer, paint, etc.) A spacer
A-1
Methods of relieving Use of materials whose potential The combination should be stainless steel/stainless
A-2 interaction between difference is small (use of the same steel, copper alloy/copper alloy, carbon steel/carbon
the materials metal) steel, etc. (The same grade is preferable.)
Provision of a longer distance between Using austenite cast iron
as a washer
materials (to lessen the potential A copper
A-3 gradient) alloy bolt Carbon steel
a) b)
Provision of a larger anode/cathode area A2/A1 = small (wrong) A2/A1 = large (correct)
ratio (A2/A1)
B-1 Stainless steel
Carbon
steel
Methods of relieving a) b)
Application of paint to the part to be the Even corrosion
corrosion damage Paint film occurs (correct)
even if interaction cathode
B-2
exists Local corrosion
Paint film
occurs (wrong)
Making the anode material replaceable Using carbon steel for bolts that are
B-3 (Treating it as an expendable part) easy to replace (large-sized ones) and
replacing them from time to time
You should understand that the word “corrosion potential series” that often appears when discussing galvanic
action just means an order and has no relation to the speed of galvanic action. For example, it is a well-known
fact that if the speeds of consumption of a zinc plate are compared between two cases, one where a zinc plate is
made to contact a stainless plate whose area amount is the same as that of the zinc plate (the potential difference is
1.0 V or less) and the other where the zinc plate is made to contact a carbon steel whose area amount is the same
as that of the zinc plate (the potential difference is 0.5 V or less), the speed of consumption of the zinc plate in the
latter case is faster by as much as 30 times at maximum than the former case.
4.2 The Electrochemical Protection Method
The cathode corrosion prevention method where the surface electric potential is made to be the base potential
is the most popular among electrochemical protection methods in the seawater environment. The anode
corrosion protection method where the surface potential is made to be the passive state potential is not practically
used because this method sometimes dangerously accelerates anode dissolution in crevices in a complex structures.
There is the impressed current method and the galvanic anode protection method (the sacrificial anode
method), but the former is relatively rarely used. For the impressed current method, it is necessary to install an
insoluble electrode (graphite or magnetic iron oxide electrode) at the fluid surface and to connect the lead wires
extended from the outside power source with each part. For this method, it is necessary to devise a special fixing
measure so that the fixed parts do not interfere with the fluid flow. And since corrosion damage to parts that are
made of stainless steel sometimes occurs during suspension of operation (installation, periodic inspection, etc.)
when the flow in the equipment also stops, in some cases, unexpected damage occurs because electricity is not
supplied during these periods. And an inappropriate design may cause overprotection in certain cases, resulting
in separation of the paint film or the lining due to the large amount of hydrogen gas generated at the cathode.
Also, in certain cases, severe corrosion damage may occur due to chlorine gas with strong oxidizing power in
equipment whose valve is left completely closed.
On the other hand, this kind of bad effect seldom occurs in the case of the galvanic anode protection method
because the current amount is relatively small. Aluminum (current efficiency: 80%) or zinc (current efficiency:
95%) rather than iron or steel should be used for the anode to be attached because they are cheaper and their self-
electrode potential is lower than iron or steel (71). Mg, when attached, provides too low an open circuit potential
and lower current efficiency (fast consumption), causing overprotection in certain cases.
It is necessary to periodically replace the anode because the anode is consumed when the galvanic anode
protection method under discussion is used. When a replacement period longer than that of the periodic
inspection is desired, it is important to reduce the value of the [protected area/area of the anode]. However, it
becomes important to pay as much attention as possible to the reliability of the heavy corrosion protection coating
when it is difficult to attach many anodes. You should expect very fast consumption of the anode when a carbon
steel part with a large area is exposed to fast-flowing seawater.
329
3.5 Power Generators
3.5.1 Preventive maintenance of electric and control facilities and remaining life assessment technology
3.5.1.1 Turbine generator
Securing the reliability of the turbine generator is a very important issue from the viewpoint of stable supply of
electricity.
The major reasons are that the percentage of each machine in the system has been increased and the rate of
shutdown of large-capacity generators due to accidents is high in the world. In addition to the increase in the
aged thermal power plants, thermal power plant units can be managed more effectively than before. Middle
management of existing units increased, and strict management of power facilities is obliged, resulting in
acceleration of deterioration.
In order to prevent severe accidents that require long-term shutdown and high cost for repair, improvement
based on various knowledge in the field and careful inspections are required. In addition, even after starting the
operation, it is important to detect accidents at the initial stage by various failure diagnosis methods and take
proper measures for them.
Preventive maintenance and remaining life assessment technology of turbine generators are introduced below.
330
Concerning dielectric breakdown that is peculiar to electric power generators in particular, active studies are
made including the sampling investigation of actual coils.
331
During production and precision inspection
Inspection Check of
properness
During
operation
Deterioration of
creep strength Accumulation
Abnormal operation
of starts and
Asynchronous High- Deterioration of stops
operation temperature low-cycle fatigue Cracks
Unbalanced operation tank strength Centrifugal
High-frequency stress during
operation operation Superimposed
Overexcitation start/stop and
operation Reverse phase high-temperature
Excessive speed current Electric creep
operation High-frequency corrosion trace
Short circuit accident current
Re-close operation Progress of Serious
cracks accident
Periodical nondestructive
inspection
In general, it is desirable to perform wedge diagnosis by ultrasonic flaw detection from the rotor surface in the
first year after starting operation and every 4 years. It is also desirable to perform visual inspection by 100%
sampling and precision inspection by dye penetration flaw detection every 8 years. The interval of “every 8
years” was decided with proper allowance based on the occurrence of cracks in the superimposed test of creep and
fatigue of high-strength aluminum at high temperature and the progress speed in Fig. 3.5.1-2. This is preventive
maintenance with the intention of inspection of the field magnetic coil by pulling the retaining ring along with
wedge sampling. This creep crack progress speed should be controlled yearly regardless of the operation mode
because static creep, depending on the operation hours, is dominant in the high-temperature field, and dependence
on the number of starts and stops is low. In the low-temperature field, the rate of starts and stops is dominant,
and closer inspection of DSS machines is desirable.
(DSS operation)
(Continuous operation)
Knowledge on the progress of creep cracks is valuable data obtained in the wake of total-loss accidents of
turbines and power generators due to damage and splash of the wedge of the industrial power generators in the
332
1970s.
In the remaining life evaluation, the presence of thermal influence is checked by confirming wedge hardness.
Defects are detected by ultrasonic flaw detection or magnetic powder flaw detection. The crack size is evaluated
by the superimposed creep and fatigue from the actual stress.
3 years
SCC progress speed 2.5~3.3 mm/year
Inspection history and SCC progress condition
After removing 6 mm
SCC defects during deletion
Fig. 3.5.1-3: Example of SCC of domestic industrial machine
As preventive maintenance, in the same way as the wedge, ultrasonic flaw detection from the external surface
is used at periodical inspection, and the entire surface is dyed for flaw detection when the ring is pulled at
precision inspection.
SCC in the retaining ring occurred because it was exposed to a wet atmosphere. It is important to keep the
gas temperature in the machine above the dew point while the machine is stopped for a long period of time, and to
take moisture-proof measures of the retaining ring during open inspection. Dewing can be prevented by keeping
the retaining ring temperature higher than the ambient temperature by several degrees. The hot air-type heater,
heater, or lamp irradiation is effective.
Exchanging the retaining ring of the hydrogen-cooling device with a rotor of a large diameter is promoted. It
is also necessary to exchange the air-cooling-type power generator or exciter of small capacity promptly.
Because the retaining ring has the maximum stress among turbine power generator rotors, it is necessary to
confirm that there are no cracks by the above-mentioned periodical precision inspection even if the material is
18Mn18Cr that has overcome the problems of SCC.
333
Insulation
Retaining ring cylinder Polar connection
conductor
section
Lead conductor
Rotor shaft Rotating span
Stopped span
Retaining ring
Insulation cylinder
#6 coil
Retaining ring #7 coil
(Insulation cylinder side)
#7 coil
#6 coil
Flexible section
334
Double-coil copper band Connection between coppers Coil of parallel section
Coil of taper section Slot
Gap at slot assembly launching
Copper powder
If copper powder accumulates in the slot, there is a possibility of short circuit or earth fault as shown in Fig.
3.5.1-8. Some accidents have been reported in the U.S. Because the copper powder increases along with the
increase in the turning time, it is necessary to clean it at an early stage. Countermeasures include the method of
fixing layers by dot brazing by eliminating relative sliding in the same turn consisting of multiple coils and the
method of inserting an insulation sheet between conductors.
Rotor wedge
Clippage block
Short circuit between coils
(if failure also occurs in other slots)
Rotor grounding
Slot insulation
Turn insulation
335
to the insulator and deformation of the conductor without disassembling the lead wedge.
Centering ring
Inspection
Lead wedge
Insulation plate
Lead conductor
(Flexible)
The soundness of the lead wedge is confirmed by the ultrasonic flaw detection test in which the lead wedge is
inserted to the rotor shaft and, if possible, by magnetic powder flaw detection inspection after the lead wedge is
pulled out.
Recently, the flexible type has been replaced with and improved to the solid type for improving reliability and
for facilitating and securing inspection.
Inspection
Fiber scope
Lead conductor
(Solid) Terminal stud
Lead conductor
rise section
Fig. 3.5.1-10: Solid-type field magnetic coil lead
3.2 Stator
3.2.1 Transition in insulation method
The capacity of the turbine power generator has been increased and the size has been reduced mainly by
improvement of the cooling method and development of the insulation system. Stator coil insulation of the
rotating electric machines including the turbine generator mainly consists of mica with superior corona resistance
and impregnated resin for holding the mica.
As shown in Fig. 3.5.1-11, the impregnated resin of natural resin (shellac resin, asphalt compound, etc.) was
used. Along with development of synthetic resin with superior heat resistance, polyester resin and epoxy resin
came to be used. Polyester resin has been used from the middle of the 1950s, and epoxy resin has been used
from the late 1950s.
Year
Because the characteristics of polyester resin are lower than those of epoxy resin, epoxy resin is mainly used
recently.
Flake mica was used as mica base at first. Laminated mica (crushed flake mica) has been used from the early
336
1960s. At present, flake mica and laminated mica are used depending on the voltage level, coil dimension, etc.
Because it has become difficult to obtain flake mica of good quality recently, the use of insulation systems with
laminated mica is increasing.
It is necessary to eliminate the void in the insulation layers of the stator coil to the extent for the prevention of
corona. For this purpose, impregnated resin is used. The resin impregnation method is generally classified into
two: the vacuum pressure method (VPI method), and the resin-rich method. The vacuum pressure method of
the coil was used for synthetic resin mica insulation at first. In the middle of the 1960s, the resin-rich method
came into practical use. In this method, semi-cured mica tape is used, and an insulation layer is formed by
pressurization and heating after taping. At present, both the vacuum pressure method and resin-rich method are
used depending on the voltage level, power generator dimension, or the production facilities of the maker.
On the other hand, the synthetic resin insulation that has been used recently has high heat resistance, and the
influence of heat deterioration is small. However, as shown in Fig. 3.5.1-13, voiding and peeling occur mainly in
the insulation layer due to the compound effect of the mechanical stress in the heat cycle along with the change in
load, starts and stops. In the operation after that, voiding and peeling grow and progress and partial discharge
occurs, resulting in dielectric breakdown(7).
Main insulation
layer
Wire
Tape layer
Void
Peeling
Wire insulation
Fig. 3.5.1-13: Deterioration of insulation layer
In addition to the above-mentioned dielectric breakdown in the main insulation layer, in the case of the
synthetic resin insulation, damage (vibration spark) to the coil surface is reported. The mechanism of occurrence
of vibration sparks is as follows.
Because the synthetic resin insulation has the characteristics of heat contraction over time, the coil is loosened
and the coil is vibrated by the magnetic force. On the other hand, a low-resistance shield is applied on the coil
surface to prevent surface corona. Almost the same voltage as the coil occurs in this low-resistance shield.
Along with coil vibration, the contact point on the coil surface and iron core moves and partial discharge
(vibration spark) occurs on the coil surface, resulting in damage to the coil surface.
To prevent these, a liner with a spring function is inserted for absorbing the heat contraction of the coil and
337
wedge.
edge. Inspection of wedge looseness at periodical inspection and re-insertion of the wedge, if necessary, are
also effective measures to prevent these phenomena.
AC
Applied voltage (kV)
4 Dielectric tangent test
(3) AC test
The current-voltage characteristics when AC voltage is applied change depending on absorption, pollution,
dielectric breakdown, and partial discharge. Insulation properties are estimated from these characteristics.
at E ≥22,000 NG
Nq ≥2.0 Surface
qmax at 1.25E/ 3 discharge is
≥30,000 dominant.
Insulation resistance
2E+1 kV 2E+3 kV 2E+1 kV 2E+1 kV 2E+1 kV 2E+1 kV 2E+1 kV 2E+3 kV
required for operation
339
3.2.5 Remaining life evaluation method
There are varieties of models and ratings of power generators. The operation conditions including
management methods, start/stop frequency, and operation hours are also diverse. There are various
nondestructive remaining life estimation methods considering these, and examples of applications are shown in
Table 3.5.1-4(9).
Table 3.5.1-4: Example of application of estimation of remaining life of power generator stator coil
[Nondestructive method]
Estimation method Method Outline
Operation history method NY map
Obtained from operation hours and number of
Operation condition
start/stop times
Equivalent operation time
Insulation diagnosis method D map Obtained from discharge parameter ∆ and max.
discharge charge amount
Max. discharge charge amount Obtained from max. discharge charge amount
Nondestructive electric test Obtained from each test amount of AC,
dielectric tangent, and partial discharge
340
Remaining withstand voltage
T(99.9% reliability lower-limit value)T
Number of starts/stops X1
(×10P3P times)
Operation hours (×10P4P h) X2
Fig. 3.5.1-15: Relation between remaining withstand voltage and operation conditions
Average
Average - 3σ
Average
Data range
Average - 3σ
341
Remaining breakdown
Discharge parameter
∆ (=∆B2B+∆B1B) (%)
voltage
Average by least
square
Fig. 3.5.1-18 Relation between estimated value Vp and measured value VR by D map method
QBmaxB (Coulomb)
The investigation result of the relation between Qmax and VR/E from various power generator coils and
sampling coils is reported. This is shown in Fig. 3.5.1-20. A certain correlation can be recognized between
Qmax and VR/E. “1×104 pC: Caution needed” and “3×104 pC: NG” are proposed as judgment standards.
342
Max. discharge intensity qBmaxB (pC)
Withstand
insulation
required for
operation
[3] Estimation by the multiple regression method from nondestructive electric test
In the following formula, the statistical correlation between the destructive voltage collected from the sampling
coil of the epoxy resin insulation and the insulation diagnosis data is calculated, and the remaining breakdown
voltage (% indication, taking BDV at production as 100%) is estimated.
BDV (%) = 91.1 – 0.767 ⋅ (∆I12) – 0.151 ⋅ (∆tanδ12) – 1.78×10-6 ⋅ (qmax12)
BDVav (%) = 42 – 29.2 ⋅ ln((BDV – 99.4)/(-56.1))
BDV3σ (%) = BDVav – ((95.3 – 0.395 ⋅ Y) ⋅ (57.9 + 0.474Y – 0.0405 ⋅ Y2))
Here,
BDVav (%): Average remaining withstand voltage
BDV3σ (%): Remaining breakdown voltage of variance 3σ
Y: Operating years
The relation between the estimated destructive voltage and measured value is shown in Fig. 3.5.1-21. The
correlation coefficient is as high as 0.61. An example of the relation between the operating years estimated by
this estimation method and the breakdown voltage is shown in Fig. 3.5.1-22. This estimation method uses the
actual insulation diagnosis data and operating years. The remaining life reflecting the actual dielectric
breakdown condition can be estimated.
Estimated BDV by multiple
regression equation (%)
343
Batch average
Batch lower limit 3σ
BDV(%)
Withstand insulation required for operation: 2E+1 kV
Hygrothermal aging
Insulation layer
Fig. 3.5.1-23 Structure of clip section and water penetration to insulation layer
If the cooling water penetrates into the insulation layer, the insulation characteristics drastically lower due to
hygrothermal aging. It is necessary to confirm formation of the water path (leak path) and penetration of the
cooling water into the insulation layer.
Presence of a leak can be confirmed by the coil pressure storage test, vacuum storage test, and tracer gas test,
etc. To judge the absorption degree of the insulation layer, the method of measuring the capacitance of the
insulation layer, which focuses on the difference in the relative permittivity between the water and the insulator, is
put into practical use, and is effective. A schematic diagram of measurement is shown in Fig. 3.5.1-24.
Coil
A large difference in relative
permittivity between the wire Upper coil
insulation layer and water
(1:20) is used.
Pressing force
3-phase batch short circuit
Capacitance between the coil
(copper) and the insulation
layer is measured to judge the
Electrode Lower coil
absorption degree to
insulation layer.
Principle
Capacitance meter
Measurement method: 100% measurement of turbine side,
collector side, and upper/lower coils
344
There is another method of estimating the remaining life by obtaining the dielectric breakdown speed by
hygrothermal aging from the capacitance and destructive voltage of the absorbed insulation layer. As shown in
Fig. 3.5.1-25, it is used for examination of the maintenance program. It is important to execute the leak test and
capacitor measurement test periodically. It is important to execute the leak test at each periodical inspection and
to consider the number of years from the initial water supply in the capacitance measurement test.
Slide
Ripple spring
Upper coil
Lower coil
Ripple spring
Stator wedge
Ripple spring
Filler
Upper coil
Lower coil
When the tapered bottoms are overlapped and inserted in the axial direction, stress is applied to the slot bottom
and the wedge is securely fixed in the slot. There is another structure to fix the wedge by adjusting the filler
thickness.
All parts for fixing the stator coil including the wedge are made of insulators. The stator coil is loosened due
to vibration or temperature after a long period of operation. If operation is continued in this condition, discharge
345
between the coil surface and the slot wall is accelerated, and the insulation layer is damaged. There is a
possibility of a ground fault accident.
Consequently, when the rotor is pulled out, it is necessary to check adhesion of the insulator powder of the
wedge to the iron core visually. It is also necessary to check the hitting sound by the test hammer and the
deformation of the ripple spring under the wedge. If the wedge does not satisfy the judgment standard, proper
measures must be taken.
Power generators are frequently started and stopped recently. The insulators tend to become loose, compared
to the base load machines. It is necessary to inspect and control the machines based on the operation condition.
α radiation
source
Rotor
Probe
Search coil
Probe details
Lead wire
Stainless pipe
N pole
N pole Layer short circuit
In another method, layer short circuit is detected from the tendency of the changes in the rotor wire impedance
due to the turning speed. If layer short circuit occurs, the inductance of the coil decreases. An small AC
current is supplied to the rotor wire by a constant current generation device. The rotor voltage is measured, and
the rotor impedance at each rpm is measured to judge the presence of layer short circuit. The rotor impedance
characteristics are shown in Fig. 3.5.1-31. The impedance characteristics of the coil with layer short circuit
change drastically. By comparing characteristics, the presence of layer short circuit is judged(18).
Impedance (Ω)
347
Detection of phase Waveform Average stress
Detection of strain Damage calculation
difference smoothness (Fatigue life
amplitude
consumption)
Static vibration Peak count method
Rotation change
ingredient
Display request
1st
unit
Display device
5th c Monitor TV
d Oscilloscope
e Digital printer
Modal conversion
constant
multiplication
Delay unit
Data Stress
Power generator Abnormal stress
current recorder Additive waveform Alarm
detection
Power generator synthesis
voltage
[Bathtub curve]
wedges: f (t)
348
3.4.5.2 High-pressure motor
In thermal power plants, high-pressure motors are used for various devices for driving accessories. High-
pressure motors are sometimes one of the important devices in a plant. To secure the reliability of the systems of
thermal power stations, preventive maintenance including periodical maintenance, exchange of parts, and
estimation of remaining life by deterioration judgment are performed for the motors of accessories.
Here, the high-pressure basket-type inductive motor is taken as an example, and an outline of preventive
maintenance and remaining life diagnosis is given.
Note) The failure is located at the stator and the coil end.
Fig. 3.5.1-35: Transition in cumulative failure rate of each failure of 3 kV basket-type motor
1.3 Control items, deterioration form, and diagnosis method of major sections
Deterioration of major sections of the motor is classified as follows:
[1] Thermal cause
[2] Electric cause
[3] Physical cause
[4] Mechanical cause
[5] Chemical cause
Deterioration is accelerated by a combination of these causes, and failure occurs. The causes of deterioration
are shown in Fig. 3.5.1-36. Examples of control items, deterioration form, and diagnosis method are shown in
Table 3.5.1-5.
349
Electric cause Thermal cause Physical cause
Table 3.5.1-5: Control items, deterioration form, and diagnosis method of major sections
No. Control Control items Deterioration form Diagnosis method
locations
Pollution Dust accumulation, corrosion, damage • Visual
1 Appearance Discoloration Paint discoloration, peeling, etc. • Visual
Loosening of each part Screw loosening, backlash, etc. • Visual, hitting
Sound Looseness, backlash, bearing failure • Sound and frequency analysis
Vibration Mechanical unbalance, layer, wire breakage • Vibration measurement, frequency analysis
Odor Degradation of insulation characteristics, • Odor judgment
burning of bearing, lubrication failure
Smoke Degradation of insulation characteristics, • Visual
Operation lubrication failure, overheating of bearing
2
condition
Voltage Layer, wire breakage • Voltage monitoring
Current Pulsation of current by cutting of basket-type • Current monitoring
rotor conductor
Temperature Bearing lubrication failure, dust • Thermometer
accumulation on cooling passage,
degradation of cooler characteristics
Lubrication oil Oxidation, lowering of viscosity, mixing of • X-ray fluorescent analysis
water or foreign materials
Slide Oil ring Deformation • Visual
Related to bearing
It is understood that daily inspection is very important for early detection and countermeasures against
deterioration. Examples of the standard inspection intervals are shown in Table 3.5.1-6.
350
2,000 ~ 3,000 operation hours Approx. 8,000 operation hours/starting 500 Approx. 8,000 operation hours/starting 500
Within 1 year max. times times
Within 2 years max. Within 2 years max.
The rotor is not pulled out if Pulling out of rotor The degree of inspection depends on the
there is no failure when the presence of problems at a previous inspection
shield is (partially) removed. and during operation.
{ Inspection of coil end In addition to initial inspection items;
• Loosening of spacer { Iron core inspection After approx. 8 years, pull out the rotor again
• Loosening of iron core for detailed inspection.
• Loosening of string
{ Loosening of tightening • Loosening of duct piece or finger
bolts { Inspection of stator wire
• Rotor frame • Loosening of wedge
• Bearing { Inspection of rotor wire
• Terminal • Bar or short-circuit ring
{ Investigation of dust and • Brazing section
stains { Slip bearing
{ Inspection of lubrication oil
• Peeling, cracks, wear, or hitting of white
{ Starting time, vibration metal
• Oil ring
[3] AC test
In the AC test, the relation between the current (I) and the voltage (V) when AC voltage is applied to the
insulator, that is, the I-V characteristics, are checked to see the insulation property. The characteristics values of
∆I (current increase rate) and Pi (current rapid increase voltage) are obtained.
351
[4] Partial discharge test
If any voids exist in the insulator, partial discharge occurs at the void when AC voltage is applied. This
discharge is called “partial discharge.” In this partial discharge test, insulation properties including wire
insulation voids and partial insulation defects are investigated, and Qmax (maximum partial discharge charge
amount) is obtained.
Table 3.5.1-7: Example of dielectric breakdown judgment standard of high-pressure rotor wire
Column No. I II III IV V
Insulation
Compound Compound Varnish Resin Resin
Application method
range Rated
3.3 kV 6.6 kV 3.3 kV 3.3~4.4 kV 6.6~11 kV 3.3~11 kV
voltage
Judgment OK OK OK Caution needed NG OK OK OK
R [MΩ] ~100~10~ >E+1
RC [Ω⋅F] >10
log (Rd/Rw) <3
P.I >1.5 >1.5 ~1.5~1.0~ >2.0
tanδ0 [%] ~20~30~ <10
at 1.25E/ 3 <0.9
∆tanδ [%]
at E <0.7 <6.5 ~0.7~1.1~
∆tanδ+∆C/C0 [%] at E <12
P11 >E
pi [kV]
P12 >3.3 >6.6 ~4.6~3.0~
at 1.25E/ 3 <2.5
∆ [%]
at E <4.0 <8.5 ~4.0~5.9~
q>500 pC ~1.9~1.3~
Vi [kV]
q>1000 pC >E
N [Pcs/half cycle]
~50~100~
at E, q>500 pC
at E/ 3 <10000
qm [pC] at 4.5 kV <10000
at E <5000 ~1000~1400~
352
sample is used to obtain some heat analysis values using the heat analysis device.
The correlation between the physical characteristic values and heat analysis value is examined to obtain the
best relation. This is called the master curve. It is obtained for each insulation material. The master curve is
the principle of this test method. An example of a master curve is shown in Fig. 3.5.1-37.
The heat analysis value is obtained from the materials that are sampled from the machine by the heat analysis
test. It is applied to the master curve of the material to estimate the physical characteristic value. (See Fig.
3.5.1-37.)
3.2 Bearing
3.2.1 Roll bearing diagnosis machine
The bearing is an important part of the rotating machine. As mentioned before, the failure rate is rather high.
It is very important to detect the failure before fatal errors occur.
The life of the roll bearing is particularly short among structural parts of the motor. The life is defined with
99% reliability. The life is mainly judged by the occurrence of flaking. Flaking is fatigue breakdown on the
surface caused by repeated stress on the rolling contact section. Due to this fatigue, the surface peels off in
flakes.
To detect this kind of abnormal phenomena, bearing vibration is detected by acceleration and enveloped. By
this method, according to the enveloped vibration acceleration data, the calculation circuit that is weighed
according to the failure type is passed, and the presence of failure is numerically converted to facilitate judgment.
Afterword
An outline of the preventive maintenance and remaining life diagnosis of the high-pressure motor is introduced
here.
It is desirable to continue a close relationship between makers and users for future development and
improvement of these technologies.
354
3.5.1.3 Electric facilities in the plant
Many thermal power plants in Japan were built between the 1950s and 1970s. More than 70% of units have
been operated for 15 years or more. The number of plants used for 15 years or more will increase in the future.
In addition, for stable supply of electricity and economical merits of extension of life, recent themes of study are
to diagnose the aged facilities properly and effectively execute life control and preventive maintenance based on
the diagnosis result.
From this point of view, as a typical device of the electric facilities of thermal power plants, an outline of
remaining life diagnosis and preventive maintenance of the static devices (including the main transformer,
transformer in the plant) and high-/low-pressure switch gear (including the metal clad, power center, and control
center) is given here.
1. Transformer
Transformers in thermal power plants include the main transformer for increasing the power generator voltage,
starting transformer for supplying the plant-starting power source, and the transformer in the plant for supplying
the power source during normal operation. Based on the concept in Table 3.5.1-9, daily inspection and
periodical analysis investigation of the insulation oil-dissolved gas are performed for these transformers. In
addition, internal detailed inspection and overhaul are performed at the time of exchange of parts with relatively
short life and at periodical inspection of the plant to secure reliability(1)-(7).
Along with the increase in the number of devices that have been used for 20~30 years, it is important to
execute deterioration diagnosis of oil-immersed transformers and estimate the remaining life from the view points
of effective use of devices and securing reliability. The oil-immersed gas analysis is widely used to diagnose
device failure. The method is widely known as the “Electric Technology Research Association method(1) (5).”
Here, we focus on remaining life diagnosis mainly by deterioration.
355
Table 3.5.1-10: Maintenance control value of insulation oil after starting operation
Voltage level 11~77 kV 110~275 kV ≥500 kV Tap switcher
Standard value Test frequency Standard value Test frequency Standard value Test frequency Standard value Test frequency
c <40 Once/3 years <30 Once/3 years <20 Once/3 years ⎯ Once every 3
years or once
Water
(ppm)
d 40~50 Once/year 30~50 Once/year 20~30 Once/year ⎯ every 50,000
times of
e >50 Countermeasures >40 Countermeasures >30 Countermeasures ⎯ operation if a
hot-line washer
c >30 Once/3 years >40 Once/3 years >50 Once/3 years >20 is provided; once
Dielectric
every 20,000
breakdown
d ⎯ ⎯ 30~40 Once/6 months 40~50 Once/6 months ⎯ times of
voltage
switching
(kV)
e <30 Countermeasures <30 Countermeasures <40 Countermeasures ≤20 operation if it is
not provided.
c >1×1012 Once/3 years >1×1012 Once/3 years >5×1012 Once/3 years ⎯ Take measures if
Volume
the voltage is 20
resistivity
d >1×1011~>1×1012 Once/year >1×1011~>1×1012 Once/year >1×1011~>5×1012 Once/year ⎯ kV or less.
(Ωcm)
(80°)
e <1×1011 Countermeasures <1×1011 Countermeasures <1×1011 Countermeasures ⎯
1.1.2 Insulator
The temperature of the insulating paper that is wound on the wire is the highest. The insulating paper tends
to be affected by degradation of characteristics caused by deterioration. Oil-immersed dielectric breakdown
strength, which is an important characteristic of the insulating paper, is not lowered by deterioration, in the same
way as the insulation oil. No problems normally occur even after the long-term operation of the transformer.
Tensile strength, which is another important characteristic of the insulating paper, is degraded due to deterioration,
and problems might occur when operation is continued. For example, when a system ground fault accident (2-
wire ground fault, etc.) occurs, external ground-fault or short-circuit current is applied. The tensile stress
functions to the wire coating due to the magnetic mechanical strength that occurs on this occasion. When the
strength of the insulating paper lowers below the strength, the insulating paper is torn or broken. This is the end
of the life of the insulating paper. It is in fact impossible to exchange the wire insulating paper of the transformer.
If the transformer is continuously used, the wire must be exchanged.
According to the above, the life of the transformer depends on the tensile strength of the insulating paper that
is wound on the wire.
No addition { z
Oxygen addition
Water addition
Fig. 3.5.1-40: Relation between remaining rate of average degree of polymerization of insulating paper and
furfural generation amount
357
desirable to replace them with new ones.
On the other hand, if the insulating paper comes to the end of its life, the wire needs to be replaced. In this
case, the major structural parts of the tank and iron core can be reused. In the case of important transformers
with a high utilization ratio and without a spare device like a major transformer, it is necessary to change it at a
proper timing in the plant life cycle in a well-planned manner.
2. Switchgear on switchboard
Switchgears on the switchboard (hereafter called “switchgears”) are classified into two: the metal-clad
switchgear that has a 6 kV-class magnetic circuit breaker, SF6 gas breaker or vacuum breaker, and the power
center that has a 600 V-class air circuit breaker.
The switchgear consists of structural parts and control accessories. Structural parts include the breaker,
protection relay, measurement transformer, and bus bar. Control accessories include the lamp, fuse, auxiliary
relay, and timer.
For extension of the life of equipment and evaluation of soundness, it is important to take proper measures for
the major devices and insulators by remaining life diagnosis in the appropriate time. Concerning the control
accessories, it is rational to update them in a well-planned manner, referring to the estimated usable years.
Remaining life diagnosis technology and preventive maintenance of major structural devices and parts of the
switchgear are introduced below.
358
Table 3.5.1-11: Life evaluation method of major structural parts of switchgear
Switchgear Major structural Cause of Soundness Life evaluation method
Failure mode
types parts deterioration evaluation Nondestructive Destructive
Insulation bus Dielectric Temperature VI Partial discharge Withstand voltage limit
wire breakdown Insulation characteristics test
resistance
measurement
Bus wire support Dielectric Humidity, VI Measurement of Material characteristics
breakdown pollution Insulation pollution degree investigation
resistance
measurement
PT, CT Dielectric Humidity, VI Partial discharge Material characteristics
breakdown corrosion characteristics investigation
Elevating Operating failure Wear VI ⎯ ⎯
structure Operation test
Auxiliary switch Operating failure Temperature, VI Contact ⎯
humidity, Conductivity resistance
Metal clad
359
the nondestructive method.
Typical evaluation methods are explained below.
AE sensor AE amplifier
Digital oscilloscope or PC
measurement system
Coupling
capacitor
RF output
Electrode
Partial
discharge
measurement
device
Figure 3.5.1-42 The change of the strength of MBB phenol bushing over time
(3) Accelerated deterioration test
The aged deterioration of insulators is accelerated by the heating conditions, and equivalent evaluation is
360
performed by the check in a short period of time. An example of the characteristics of tensile strength to the
same insulator is shown in Fig. 3.5.1-43. The parameters are “T” (heating temperature) and “t” (heating time).
If the used temperature can be seen from the characteristics, the life of the standard strength can be estimated.
→ Break strength
(kg/mmP2P)
Temperature
Standard strength
→ Time
361
To select the range, future operating hours, economic efficiency, and time required for updating need to be
comprehensively compared. In the case of parts exchange, if the control center type is old, it might be difficult
to acquire parts because of model change by makers or it takes a long time for exchange. It might sometimes be
necessary to remodel existing panels to use a new incompatible part. Unit exchange might be more economical
than parts exchange.
Afterword
Many electric facilities in plants have been used for 25 years or more. Reliability has been maintained by
periodical inspection, exchange of parts with short life, or horizontal development of nonconformity. In order to
use these aged facilities for a longer period in the future, it is strongly desirable to establish life diagnosis and
evaluation technology of wires that are the major structural parts, like transformers.
For this purpose, cooperation between the maker and users is effective. We need the understanding and
cooperation of related parties.
362
3.5.2 Corrosion of power generators and countermeasures
Power generators can be classified by their cooling method: air cooling and hydrogen cooling (including stator
cooling). Corrosion problems due to the water environment are common to both methods.
In this chapter, examples of the corrosion of the structural parts of power generators are shown. Causes and
countermeasures are introduced and explained.
If water leaks from the cooler (water-hydrogen-type and water-air-type heat exchanger) in the power generator
or cooling water circuits of the cooling water coil due to damage caused by corrosion, serious and fatal accidents
such as short-circuiting or ground fault may be caused because the power generator is an electric machine.
Because the turbine power generator is an electric, high-speed rotating machine, the structural parts of the rotor
must have a structure resistant to strong centrifugal force. The retaining ring is an important part of the rotor,
and some accidents have occurred due to stress corrosion cracks. In the following section, serious corrosion
problems and countermeasures are explained.
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3.5.2.1.2 Corrosion cases of water cooling coil and countermeasures
The purity of the water used for the water cooling power generator is high. The frequency of corrosion is
much lower compared to general devices. Cooling water does not leak from the stator coil due to corrosion.
Corrosion progresses very slowly from past experience. Corrosion product materials are deposited only in the
filters or pipes. Major ingredients of corrosion product materials are CuO and Cu2O. One of the parameters
related to corrosion is the dissolved oxygen concentration in the cooling water. In a system that has been put to
practical use, the primary cooling water tank is covered with air or hydrogen. The dissolved oxygen
concentration in the cooling water is high in the former case and low in the latter case. Both are operated in
good condition under a stable dissolved oxygen concentration condition. However, it is regarded that there is an
area where corrosion tends to occur in the middle of both concentrations. It is important to control the dissolved
oxygen concentration for various reasons such as the plant operation method. Figure 3.5.2-2 shows the relation
between the dissolved oxygen concentration and the corrosion amount.
Relative value of corrosion
Measurement point
progress speed (p.u.)
Fig. 3.5.2-2: Relation between dissolving oxygen concentration and corrosion progress speed
The experiment result of the air dissolved condition in Fig. 3.5.2-3 clearly indicates this. The corrosion
amount increases linearly in the case of air of 5 m/s. It saturates in the case of hydrogen or nitrogen.
Concerning the difference in the corrosion amount depending on the speed, the corrosion amount is small in
general if the speed is low. There is no large difference at 1.6 ~ 0.16 m/s.
1 MΩ or more
Period (year)
Next, the corrosion due to the current that is supplied to/from water by the application of high voltage
(hereafter called galvanic corrosion) is explained. This is peculiar to electric devices of direct cooling by water.
The current has corrosive effects only when a current is supplied between metal and water. If a current is
supplied to the hollow conductor by supplying water to the hollow conductor inside, a current is not supplied
between the water and the conductor because the conductor resistance is smaller than the water resistance.
Consequently, this way of supplying a current does not induce corrosion. The experiment result when a current
is supplied between metal and water is shown in Fig. 3.5.2-4. According to the experiment, the influence of the
current on the copper is large, and corrosion is accelerated even in the case of AC. Stainless steel (SUS304) is
extremely strong against a current. It can be considered that corrosion does not occur practically in the case of
AC in particular.
364
Copper DC⊕ 1.28 mA/cm2
Copper AC 2.85 mA/cm2
Copper DC⊕
0.1 mA/cm2
Copper AC 1.43 mA/cm2
SUS27
Temperature: 85°C
DC⊕ 0.32 mA/cm2
Dissolved gas: Air
• AC is 60 Hz.
• DC⊕ indicates the
corrosion amount on
the plus side by direct
current. Almost no
corrosion is found on SUS27 AC 2.86 mA/cm2
the minus side.
Time (Day)
Fig. 3.5.2-4: Galvanic corrosion of copper and stainless steel
In general, corrosion of corrosion-prone metal is accelerated if different kinds of metal make contact with one
another. However, along with the increase in the specific resistance of the corrosive media, the influence
becomes smaller. Consequently, it is regarded that contact corrosion problems do not occur in pure water based
on common sense. In the corrosion experiment of the low specific resistance (100 kΩ-cm) of the silver brazing
section of the stainless steel (SUS304) and copper, no contact corrosion was recognized in the galvanic pair of the
stainless steel and silver brazing.
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3.6 Efficiency and operation improvement of thermal power plants
3.6.1 Technology for improving the bearing force of boiler equipment
Boiler equipment receives various types of damage depending on the environment of use, most of which are
combinations of several damaging factors. With respect to such damage, various measures for improving the
bearing force have been taken, as shown in Table 3.6.1-1.
(1) Example of measures taken against the portions where thermal fatigue damage occurred
Most of the damage boiler equipment receives is caused by thermal fatigue. The measures taken against such
damage vary depending on the structure of each individual member. Table 3.6.1-2 shows an example of measures
taken in order to improve the bearing force.
Corrosion fatigue Change of structure and Fixture welded to the furnace wall piping,
shape, water quality bent portion of the economizer
control
Wear Coal ash, soot blow Protector, pipe thermal Furnace wall, superheater, reheater
spraying
Corrosion fatigue damage on the inner face of the furnace wall piping occurs when the strength against fatigue
is reduced due to corrosion by the inner fluid. In view of the fact that corrosion fatigue damage also occurs at the
portion where a fixture is mounted on the external side, it is assumed that thermal stress is the major cause. An
effective countermeasure is to reduce the thermal stress by improving the structure of the attached fixture on the
external side.
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Table 3.6.1-2 Example of measures for improving the bearing force of the boiler equipment
Example of measures for improving the bearing
No. Name of portion Conventional structure
force
1. Furnace wall
Wall boxes such as
burners, OAPs,
Chamfering and
inside TVs, soot R-machining of the
blowers, etc. The corner portion cracks when a corner portion
temperature difference occurs
between the furnace wall and the Provide a step to the corner portion and chamfer the
wall box in the course of the sharp edges to reduce the thermal stress. Weld the
temperature rise after starting the wall box to the fin to reduce the temperature
operation of the furnace. As the wall difference.
box has been welded to the pipe, the
temperature on the pipe side rises
rapidly, causing the temperature
difference to become larger.
2. Side wall at the
furnace outlet/portion
Steam type
welded to the side
wall of the furnace Steam type
Water cooling type
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Example of measures for improving the bearing
No. Name of portion Conventional structure
force
4. Pipe header of the Honeycomb Honeycomb
Hanging
loop pipe Improvement of the structure of the connection fixture
If any temperature difference occurs A sliding spacer should be used at the high
when starting the furnace, cracks temperature transferring portion to prevent locking,
may occur to the linked metal fitted should a temperature difference occur.
portion due to the stress The tie lag at the rear heat transferring portion should
concentration. be an oval lag to soften the stress concentration.
7. Portion passing Crown
Crown Additional
through the ceiling sleeve
Due to a temperature difference A sleeve is used for both SUS pip and 2.25 Cr-1Mo
between the crown and pipe, stress pipe.
concentration occurs, which may
cause cracks. By using a sleeve for
the SUS pipe where it passes
through the ceiling, the thermal
stress can be softened.
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Example of measures for improving the bearing
No. Name of portion Conventional structure
force
Flow nozzle
8. Devices in the spray
Venturi pipe
pipe of the
superheater
or
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Table 3.6.2-1 Preventive maintenance and technologies for improving the bearing force of steam turbine (outline)
Cause of damage
by fatigue
Corrosion
Portion subject to Preventive maintenance and technologies
Fragility
by creep
Damage
Damage
Erosion
countermeasures for improving the bearing force
Others
High/medium { { Employment of low Si content rotor
pressure rotor material
{ { Employment of improved rotor material
{ Expansion of stress softening
grooves/flattening of 1st step rotating blade
grooves
{ Expansion of corner R of dummy grooves
Low pressure rotor { { Employment of super clean rotor material
{ Employment of improved type blade
grooves
{ Integrated rotor
High/medium { Employment of ISB (integral shroud blade)
pressure rotating { Employment of large sized blade grooves
blade
Low pressure { Employment of the new type of long blade
rotating blade { Employment of snapper blade
{ Improvement of the structure of low
pressure blade (against erosion)
High/medium { Nozzle against erosion (Cr pack treatment)
pressure nozzle { Employment of improved type nozzle blade
{ Employment of boron treated nozzle
{ Employment of thermal spraying nozzle
{ Operation by injecting a full arc when
starting operation (Employment of
electro-hydraulic governor)
Low pressure { Improvement of the outer wall shape of the
stationary blade nozzle diaphragm
High/medium { Employment of high toughness casing
pressure material
internal/external { Employment of improved cast steel material
casing
Main valve casing { Forged valve
{ Employment of high toughness casing
material
Main valve rod { Alteration of valve rod and bushing material
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3.6.2 Preventive maintenance and technologies for improving the bearing force turbine equipment
Due to continuing operation of aged thermal power generation plants under severe conditions, aged
deterioration of steam turbine equipment has accelerated.
In view of the extension of regular inspection interval and enforcement of self control of the equipment under
the above-mentioned operation conditions, preventive maintenance and measures for improvement of bearing
force have become more important.
Table 3.6.2-1 outlines the preventive maintenance and measures for improvement of bearing force of steam
turbine that have been developed and employed.
(1) Turbine rotor
① Measures against creep damage and fragility
As measures against damage caused by high temperature creep or fragility of high/medium pressure rotors,
rotor material is employed that has higher strength against high temperature creep than conventional rotor material,
with low speed fragility and that corresponds to operation changes such as DSS, etc.
• Employment of low Si content rotor material
• Employment of improved rotor material
② Measures against fatigue damage
As measures against fatigue damage to the portion of high/medium pressure rotors with high level thermal
pressure, processes for removing fatigued and deteriorated layers and improving the shape are employed.
• Expansion of stress softening grooves
• Flattening of 1st step rotating blade grooves
• Expansion of corner R of dummy grooves
③ Measures against fragility
As measures against the reduction of toughness and ductility due to aged fragility of low pressure rotors, rotor
material with minimized impure chemical element is employed.
• Employment of super clean rotor material
④ Measures against corrosion
To attain improvement by changing the shapes of portions subject to corrosion and corrosion fatigue
• Employment of improved type blade grooves
• Integrated rotor
(2) Rotating blade
① Measures against creep damage
As measures against creep damage occurring to high/medium pressure rotating blades, improvement is attained
by eliminating the tenon crimped structure by integrating a blade and a shroud(ISB blade) and reduction of stress
from blade base/blade grooves by employing large-sized blade grooves.
• Employment of ISB (integral shroud blade)
• Employment of large sized blade grooves
② Measures against corrosion and erosion
As measures against failure caused by the corrosion of low pressure rotating blades, the new type of long blade
from which the tie wire has been eliminated is employed. In addition, as measures against the erosion of final step
rotating blades, the drain discharge process, etc. will be improved.
• Employment of the new type of long blade
• Employment of snapper blade
• Improvement of the structure of low pressure blade (against erosion)
(3) Nozzle diaphragm
① Measures against erosion by solid particles
As suppression/prevention measures against erosion of high/medium pressure nozzles by solid particles,
reduction of erosion and improvement of erosion resistance are attained by improving the nozzle blade type and
method of steam inflow.
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• Nozzle against erosion (Cr pack treatment)
High pressure shaft Medium pressure
shaft
Fig. 3.6.2-1 Expansion of stress softening grooves/flattening of 1st step rotating blade grooves
• Lightening cover
Cover structure • Without cover Full arc 1 ring
Blade rigidity • Low rigidity blade type • High rigidity blade type
Reduction of vibration
amplitude
Prevention of Stellite from
peeling off
Tie wire
• 12Cr • 12Cr-Nb
Material Stainless steel Stainless steel
Strength increased to
1.1 times
Conventional blade (left side)/
new blade (right side)
372
• Improvement of the external wall shape of the nozzle diaphragm
(4) High/medium pressure casing
① Measures against creep damage and fragility
As measures against crack generation/deformation or fragility caused by high temperature creep in the
high/medium pressure internal and external casing, casing material having strength against high temperature creep
and excellent roughness properties against destruction is employed.
• Employment of high toughness casing material
• Employment of improved cast steel material
(5) Main valves
① Measures against creep damage
By eliminating any and all defects contained in the cast valve and employing casing material having excellent
roughness properties against destruction, the main valve casing can be improved.
• Forged valve
• Employment of high toughness casing material
② Measures against erosion
For the main valve rod, etc., material having excellent strength against creep rupture and material generating
less amount of oxidized scale (by surface treatment) are employed.
• Improvement of material for valve rod
• Improvement of material for bushing and surface treatment
(6) Examples of preventive maintenance and technologies for improving the bearing force
① Measures against fatigue damage of high/medium pressure rotors
Examples of measures against aged fatigue damage of high/medium pressure turbine rotors are shown in Fig.
3.6.2-1. Its purpose is to improve the bearing force against fatigue by skin-cutting the fatigue deteriorated layer of
stress softening grooves and 1st step rotating blade grooves and further expanding the R of stress softening
grooves and flattening the 1st step rotating blade groove bottom.
② Measures against creep damage of high/medium pressure rotating blades
A tenon crimping structure was used for reaction step rotating blades in the past. However, it was found that
creep damage occurred to the tenon portion where the shroud’s centrifugal force was applied by high/medium
pressure rotating blades exposed to high temperature steam. As countermeasures, ISB (integral shroud blade) in
which the blade and shroud are integrated together has been employed. ISB has other effects in improving
vibration characteristics by full arc tracing structure and by improving the sealing structure.
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Casing
Stationary
blade
Drain catcher
Stationary blade ring
Rotating
blade
Trace of
water drop
Rotor
Drain
Drain
Slit
Stationary
blade
374
In addition to the aged erosion of low pressure rotating blades, not only decreased efficiency but also crack
damage may be caused by corrosion or erosion.
In order to prevent such damage, Stellite plates are bonded to the front edge of rotating blades and hardening
treatment is applied. In addition, by employing a hollow stationary blade with a slit and drain catcher and by
promoting drain discharge aggressively, the erosion of low pressure rotating blades can be largely suppressed.
Improvement of Nozzle box of upside down type Improvement of Change to cassette nozzle
ease of ease of
maintenance Common spare nozzle box maintenance Common spare nozzle
Fig. 3.6.2-5 Measures against erosion of high/medium pressure 1st step nozzles
An example of improvement of drain discharge from low pressure blades is shown in Fig. 3.6.2-4.
④ Measures against erosion of high/medium pressure 1st step nozzles ⁽²⁰⁾⁽²¹⁾
Erosion phenomenon (SPE: Solid Particle Erosion) caused by oxidized scales flying from boiler, etc. can be
detected on the 1st (initial) step nozzles of high/medium pressure turbines, which creates various issues with
respect to performance, reliability, regular inspection interval, maintenance and control, etc.
Several measures against erosion in this respect are shown in Fig. 3.6.2-5.
In case of high pressure 1st step nozzles, erosion is generated at the outlet end of the nozzle by solid particles
flowing into the steam path. The erosion can be suppressed by such diffusion penetration treatment as boron
treatment (to have B (boron) make diffusion penetration on the metal surface and form a very hard and fine
chemical compound (Fe2B) layer on the nozzle plate), which strongly adheres to the base metal and forms an ultra
hard coat.
The medium pressure initial step nozzle can be damaged when solid particles passing through the nozzle
rebound from the rotating blades. As measures against this, bearing force is improved by forming on the back of
the nozzle a 250 – 300 µm thick plate hardened coat against high temperature and stable thermal spray metal of
the carbon family mainly composed of chromium carbide by high velocity gas flame metal spraying method
(HVOF).
375