BOILER TUBE INTEGRITY PUTTING RELIABILITY FIRST

Transcription

1 ARIPPA Technical Symposium August 15th and 16th, 2017 Sheraton Harrisburg Hershey Hotel BOILER TUBE INTEGRITY PUTTING RELIABILITY FIRST Tim Batton Regional Sales Manager Eutectic Corporation Whertec, Inc Highway Ave. Jacksonville, FL USA The Reliability Experts for Industrial Process Equipment 1

2 Eutectic/Whertec, Inc. understands these truths and values: Today s power producers have more demands than ever before. As demand continues to grow, so do the demands on traditional solutions. Practice Proactive Preventative Maintenance Reduce Equipment Downtime Minimize Costly Emergency Repairs Eliminate Unplanned Outages

3 Proactive Management is a Process Identify the Problem(s) Examine Best Options Balance Cost Versus Budget Qualify Options (Products & Services) Maximize the Investment

4 Everything is Measurable & Manageable Boiler Tube Wear Power generating boilers are aggressive environments: erosive wear and high temperature corrosion have adverse effects on tube materials. Thinning of boiler tubes will lead to premature tube rupture and unplanned outages that cost millions of dollars in lost revenue and emergency repair cost.

5 Defining the Problem in $$$ 2007 Boiler Tube Failure Total Loss Commercial Availability (Jan. 1-Jun. 30)= $64,613,313 % Boiler Tube Leaks Failures Furnace Wall Tube Leaks Reheat Tube Leaks Secondary Superheater Tube Leaks Economizer Tube Leaks Primary Superheater Tube Leaks Cyclone Furnace Tube Leaks Other Tube Leaks Convection Pass Tube Leaks Percentage of Total Leaks Boiler Screen, Wing Wall or Slag Screen Tube Leaks

6 What are the Alternatives? Tube Thinning It s an increasingly costly problem The extent of the problem can be mitigated and proactively managed. The advance of coating technologies offer relief and solutions.

7 IDENTIFY ROOT CAUSES Boiler Design and Operation Wear Problems Coal Fired Boiler Erosion of pendent tubes and soot blowers. Waste Incineration Boilers Corrosion on water walls and Superheaters. Fluidized Bed Boilers - Erosion above the refractory and in-bed corrosion/erosion.

8 Metallic Shields Co Extruded Tubes Established Solution Options to Reduce Tube Thinning Change the quality and consistency of the fuel Change the boiler operations Change the design of the boiler Use refractory or shields to protect tubes Apply thin protective coating on tubes to reduce erosion and corrosion

9 CURRENT BEST PRACTICE COATING OPTIONS On Site Arc Spray HVOF Ceramic Coating Weld Overlay Arc Spray Automated setup for large parts HVOF Manual or automated setup for small or large parts Shop LaserClad Fully automated 2 heads setup for small or large parts

10 Products and Services Twin Arc Thermal Spray Flux-Cored Wire Production Chromeclad Proven Technology Optimized Arc Wire machines for boiler Specialized Wire production in house Ceramic Coating Densifier option Excellent for Corrosion AS4 Automation In-Situ

11 Cross section of Arc Wire Spray coating Arc Wire spraying Shop and On-site Options Advantages: Faster to apply, lower cost Better erosion resistance High performance alloys available Workshop and on-site potential

12 ChromeClad ELEMENT Composition (%) Ni Cr Fe Mn 0.66 Si 0.16 ChromeClad POROSITY EVALUATION An elastic, ductile coating that dissipates high impact forces to reduce gouging Coating can be read with MLO device for accurate thickness applications Repairable to extend tube life expectancy Average production rates of ft2 per hour at 20 mils ChromeClad CHEMICAL ANALYSIS High resistance to corrosion and oxidation due to chromium content Ceramic sealer used to fill in surface voids & prevent permeation of corrosive gases, debris and liquids.

13 Practical Experience in Boilers: Corrosion Protected with ChromeClad and with TubeArmor no tube loss after two years Unprotected without protection, 18.5% tube loss after two years ChromeClad on site together with Tube Amor for higher furnace area with aggressive wear Close to soot blowers, high erosion is an issue so CHROMECLAD E used as a top layer. LaserClad- Standard for lower furnace areas Inconel 622 type alloy, proven and preferred for severe corrosion applications

14 Products and Services HVOF Thermal Spray Optimized HVOF machines for boiler Specialized powder production in-house Ceramic Coating Densifier option Excellent for Erosion Specialized Gas Atomized Anti-Satellite HVOF Powders

15 Practical Experience in Boilers: Erosion Coal fired Power Stations in USA benefiting from CarbideClad On site inspection On site spraying HVOF and Densification technology. Highest density and hardness of all coatings In coal fired power plants in over 20 states in the USA since 1996 Success in primary furnace zones giving 10x longer life. Superheater tube lifespan increased by 50x over bare tube

16 Products and Services Ceramic Coating Onsite tubearmor Densification Erosion resistant Hard, heat and corrosion resistant ceramic-based film Can be applied on large surfaces and on-site, quickly and at low cost Protection against slag build up and corrosion including chlorine since 1996 Fast deposition, enhances heat transfer rates Seals coatings and gives a smooth surface

17 Heat Conductivity Related to Fuel By-product Buildup O 2 Pyrite FeS 2 + O 2 = Fe O + SO O Fe CaSO4 Tubearmor Ceramic Coating Fe Cr 1/16 Soot Furnace Gas (Pyrite) Slag Tube Metal 3/16 Soot Tubearmor Ceramic Coating Slag shedding off burner wall coated

18 Ceramic Coatings Have Erosion Resistance

19 Refractory Interface Coatings and Ceramic Tile

20 Economizer Tube Bank protected with coating

21 Products and Services LaserClad Laser Cladding full panels Laser Cladding single tubes Fully automated workshops 625, 622 and specialized powders Lower dilution, better resistance Thinner coatings, less distortion Embracing of Weld Overlay benefits while addressing disadvantages at a lower cost

22 Onsite, in-situ welding of panels Shop installed tube overlay Shop and On-site Options Advantages: Crack free, dense, thick deposit, well bonded Proven solution against corrosion Minimal dilution and distortion versus WO Can be automated and reliable

23 W. Edwards Deming a noted Engineer and Management Consultant once said: if you can't measure it, you can't control it. WHAT DOES THIS REALLY MEAN?

24 Protecting Investment Boiler Data Collection, Mapping and Reports Equals Proactive Recommendations and Accountability Proactive management minimizes cost and maximizes reliability

25 Conclusions Solutions Tube Protection a range of cost effective solutions There are new, higher performance, lower cost solutions which can be applied in a shop or on-site These processes include Arc Wire, HVOF, Ceramic Coatings, Overlay and Laser Clad and Spray & Fuse. Proactive management with quality assurances, insures proper protective coating system protection and maximum reliability of critical boiler components at the lowest possible cost.

26 FAN ISSUES HUBS and HOUSING

27 FAN ISSUES Blades

28 Introducing...Eutectic Corporation Innovative Solutions for Wear Protection

29 Services Maintenance & Repair Workshops Feed Hopper Pans Exhaust Filter Cyclone Tubes Feed Screw Bulldozer Blades Fans Custom Boxes Screens Cones

30 CDP Optimal Solution for Large Area Wear Protection X X 18X X 9X N 112 &

31 CastoTube Seamless, Internally Wearfaced Pipe Protection Against Abrasion and Erosion Produced using advanced wear resistant alloys Easy to join by welding or mechanical means Cost effective for rapid replacement of worn pipe Custom cutting, elbows and joints available Wearfaced coating withstands impact and handling

32 The Eutectic Difference Ultra-hard phases anchored in a tough matrix to combat severe abrasion. Controlled cooling produces strongly oriented hard phases for maximum wear resistance. Hardness that s typically 2-3 times higher than the most abrasive media found in industrial processes. Available in straight pipe or custom configurations such as elbows, reducers, wyes and other shapes. Conventional weld structure with random oriented hard phases. Dense dispersion of strongly oriented hard phases maximize wear resistance.

33 Wear Management Solutions Protective Coatings for Industrial Fans and Housings

34 Do These Pictures Look Familiar? Worn-out impeller Worn-out blade Extreme erosion on blades Localized abrasion on blade section Common Enemies of Valuable Fans & Housings Erosion Abrasion Cavitation Corrosion Impact High Temperature

35 Protective Coatings for Industrial Fans and Housings Extend Service Life with CDP XuperWave Wear Plate & Weld Quality Straight Bead XuperWave Bead Conventional wear plates exhibit uneven welds XuperWave welds remain smooth and even Ideal for parts exposed to fine particles at high velocity Maximum protection against linear erosive wear Prevents fine particle tracking at points most susceptible to wear such as the stress cracks and weld bead overlap Reduces wear by up to 30% over conventional weld bead pattern Smooth, flat bead profile for easy balancing and overall increased fan performance

36 ARIPPA Technical Symposium August 15th and 16th, 2017 In Summary: Let s Ask Ourselves... Would you install ANY protective coating system to a critical component of your equipment, and then walk away? No you would not. This is a critical and costly investment where the ROI is measured in terms of maximum reliability. Tim Batton Regional Sales Manager tim.batton@whertec.com Eutectic Corporation Whertec, Inc Highway Ave. Jacksonville, FL USA The Reliability Experts for Industrial Process Equipment